MAHARANA PRATAP UNIVERSITY OF AGRICULTURE AND TECHNOLOGY UDAIPUR (RAJ.

TRAINING REPORT ON

CNC Machine

SUBMITTED TO DR. M.A. SALODA Sir MECHANICAL ENGG. DEPARTMENT

SUBMITTED BY GAUSWAMI PRASHANTGIRI BE 2nd Year(Mech.)

ACKNOWLEDGEMT

I would like to thank HIMSON ENGINEERING PVT. LTD. SURAT for providing me an opportunity to work with them. The support and the environment provided to me during my project was more than what anyone would have expected.

I owe my profound gratitude to Mr. MADHUKAR AJGAONKAR who granted me the opportunity of working as a summer trainee at mechanical Division.

I would also like to thanks Mr. ASHOK PATEL (G.M.) without his support I would not be able to perform such a delightful job.

And at last I would like to thanks all the people involve in the training who help me out in accomplishing it in such a wonderful way.

INDEX 1. ABOUT THE COMPANY 2. Introduction of CNC Machine 3. Types of tools 4. Tool Material 5. Tool Geometry 6. Tool Holding 7. WORK Holding Device 8. Material Handling 9. Automatic Tool changer 10. Operation of CNC 11. List of G-Codes 12. List of M -Codes

About the company

Himson Engineering Pvt.Ltd. is the flagship company of the Himson Bhogibhai Group. It is one of the largest manufacturer of textile machinery in India with the experience of more than 3 decades. The engineering activities of the group are carried out under the direct control of Head-Quarters located at Ashwanikumar Road premises at Surat, India. Initially, in the year 1978, HIMSON tied up with Earnest Scragg Sons Ltd., UK to manufacture Draw-Texturising Machines in India. Since then, the strategy has been to acquire the best available technology from the reputed and innovative internationally leading companies and upgrade the same with help of the experts around the world in conjuction with our in-house development experts and considerably long machinebuilding experience. This strategy has worked very well and eventually, made the company successful in its field in India & Abroad. Today, the company enjoys significant market share of Synthetic Yarn Processing Machinery in India. (Supplied more than 3000 Draw-Texturising machines) the fast growth has been sustained on continuous upgradation & design and manufacturing facilities by installing most modern CNC machining centers, fabrication units and metal finishing shop in-house together with the latest Design and Development Center equipped with modern CAD/CAM facilities and latest state-of-the art designing softwares to achieve highest accuracy and maintaining stringent quality standards, benchmarked against the best in the world. Himson Engineering Pvt Ltd is accredited with ISO 9001:2000 Certification. Today, HIMSON enjoys high reputation for in-house research and technology developments and an efficient and reliable After-Sales-Services. In year 1998, HIMSON entered into a technical collaboration with M/s. Teijin Seiki Textile Machinery Co. Ltd., Japan to manufacture High Speed DrawTexturising Machines with Energy Conserving Short Heaters and Auto Doffing. 4

Himson Engineering enjoys a very respectful image as supplier of world class textile machines and is the leader in almost all the products that it manufactures. Many of the products are exported to developed as well as developing countries. The manufacturing facilities are now also offered to the Indian & International industries, to fully exploit the capacities which has been generates over the years. In the year 2008, Himson Engineering Pvt Ltd also received a prestigious order from Alok Industries Ltd, one of the leading textile unit in India for supply of Auto Doffing Draw Texturising Machine. Himson Engineering Pvt Ltd has executed this prestigious order for supply of Himson TMT Draw Texturising Machine Model ATH 12 F/V each with 288 spindles in joint corporation with world re-known TMT Japan (TMT Machinery , Inc Japan) This is the 1st time in India Auto Doffing Machines are manufactured and installed also, this the 1st time in world to supply this machine with 288 spindles.

INTRODUCTION
Numerical control (NC) refers to the automation of machine tools that are operated by abstractly programmed commands encoded on a storage medium, as opposed to manually controlled via hand wheels or levers, or mechanically automated via cams alone. The first NC machines were built in the 1940s and 1950s, based on existing tools that were modified with motors that moved the controls to follow points fed into the system on punched tape. These early servomechanisms were rapidly augmented with analog and digital computers, creating the modern computer numerical control (CNC) machine tools that have revolutionized the manufacturing process. In modern CNC systems, end-to-end component design is highly automated using computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a postprocessor, and then loaded into the CNC machines for production. Since any particular component might require the use of a number of different tools-drills, saws, etc., modern machines often combine multiple tools into a single "cell". In other cases, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine. In either case, the complex series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD design. Conventional machining, one of the most important material removal methods, is a collection of material-working processes in which power-driven machine tools, such as saws, lathes, milling machines, and drill presses, are used with a sharp cutting tool to mechanically cut the material to achieve the desired geometry. Machining is a part of the manufacture of almost all metal products, and it is common for other materials, such as wood and plastic, to be machined. A person who specializes in machining is called a machinist. A room, building, or company where machining is done is called a machine shop. Much of modern day machining is controlled by computers using computer numerical control (CNC) machining. Machining can be a business, a hobby, or both. The precise meaning of the term "machining" has evolved over the past 1.5 centuries as technology has advanced. during the machine age, it referred to and 6

as turning, boring, drilling, milling, broaching, sawing, shaping, planning, reaming,

tapping, or sometimes to grinding. since the advent of new technologies such as electrical discharge machining, electrochemical machining, electron beam machining, photochemical machining and ultrasonic machining, the retronym"conventional machining" can be used to differentiate the classic technologies from the newer ones. The term "machining" without qualification usually implies conventional machining

ADVANTAGES OF CNC MACHINE

Higher flexibility 1Increased productivity Consistent quality Reduced scrap rate Reliable operation Reduced non productive time Reduced manpower Shorter cycle time High accuracy Reduced lead time Just in time (JIT) manufacture Automatic material handling Lesser floor space Increased operation safety Machining on advanced material

CNC
Computer Numerical Control (CNC) - 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.

SPECIFICATIONS OF THE CNC MACHINE USED IN COMPANY:

FEELER PVT. LTD. Model No.-FV600 APC Serial No.-AP036 APC- Automatic pallet change (Work on the Hydraulic Pressure) Software used inside of the System : Fanuc Series 0-M Magazine: It contains 18 tools (maximum) in its pocket at a time. RPM of spindle: MAX - 10,000 Generally work on 1200 to 2500.

Center Drill Size : BS-3 to BS-14 (used as per required diameter.) Drill Size Diameter: MIN:2.5 mm MAX:30 mm Generally , ALUMINIUM metal compnents are manufactured by this machine.

Requirements of CNC Tooling

i. Higher control on reshaping and inspection should be practiced and repeatable performances. ii. Higher control should be exercised on the run out of the multi teeth cutter for better size control. iii. Cutting tool should be selected from improves design for improved quality of workpiece and spade drills, carbide drills, care drills with carbide inserts, reamers, coated inserts etc.

Construction Features of CNC Tooling

The tools for CNC machines should, i. ii. iii. iv. Be present and reset outside the machine. Be quickly changeable to deduce non cutting time. Have high degree of interchangeability. Have increased reliability because of high automation and unmanned machining.

Types of CNC Tooling

In order to reduce non productive time to zero level, quickly changeable tool such as present and qualified must be used. These tool have emerged to reduce the non productive to the minimum. There are two types of CNC tools a) Preset tools b) Qualified tools

A.)Preset tools
A presetting device is used to present axial and radial position of the tool tip on the tool holder. Once this is done, the tool holder is ready to be mounted on the machine and produce a non dimension. Presetting device to various level of sophistication is available. Tool offset, tool length, and tool diameter compensation facilities available in the present day CNC machines have brought down the importance by presetting. Accuracy in the order of from 0.0002 to +0.0002mm can be quickly and easily maintained.

B.)Qualified Tools
These are tools in which the cutting tip or edge is maintained at a fixed distance within a tolerance (from-0.05to+0.05) with respect to the reference surface of the folder. In these types of tools no presetting device is used, therefore investment is less. Rough cuts can be taken without a trial cut. Control dimensions of the tool are nominal and fixed, hence programming is easy. Set up time is reduced as elaborate organizing and planning as in preset tool is not needed. The tool need not be measured individually.

Tool materials
Tooling, surprisingly enough, is often the least understood aspect of CNC equipment. Given that it is the one element that will most affect the quality of cut and the cutting speed, operators should spend more time exploring this subject. Cutting tools usually come in three different materials; high speed steel, carbide and diamond.

High Speed Steel (HSS)

HSS is the sharpest of the three materials and the least expensive; however, it wears the fastest and should only be used on nonabrasive materials. it requires frequent changes and sharpening and for that reason it is used mostly in cases where the operator will need to cut a custom profile in-house for a special job.

Solid carbide
Carbide tools come in different forms: carbide tipped, carbide inserts and solid carbide tools. Bear in mind that not all carbide is the same as the crystalline structure varies greatly between makers of these tools. As a result, these tools react differently to heat, vibration, and impact and cut loads. Generally, low cost generic carbide tools will wear and 10

chip more rapidly than higher priced name brands. Silicon carbide crystals are embedded in a cobalt binder to form the tool. When the tool is heated, the cobalt binder loses its ability to hold on to the carbide crystals and it becomes dull. At the same time the hollow space left by the missing carbide fills up with contaminants from the material being cut, amplifying the dulling process.

PCBN (Poly Crystalline Cubic Boron Nitrate)

The PCBN tools are used for finishing heat treated alloy steels, tool steels, cast iron, powered metal, cobalt based alloy, and nickel based super alloys.

PCD (Poly Crystalline Diamond)

The PCD tools provides outstanding wear resistance and good surface finish, when machining highly abrasive non ferrous material such as aluminum, aluminum alloy, cooper alloys, and carbon and epoxy composites, hard rubber, wood, fiber glass, and plastics.

Summary of application for various cutting tool material

Tool material Carbon steel Work material Remark cutting speed, low Low strength, softer material, Low non ferrous alloys, plastics Low/medium alloy steel

strength material cutting speed, low

Low strength, softer material, Low non ferrous alloys, plastics

strength material

HSS

All material of low and Not suitable for low speed medium hardness strength and application

Cemented carbide

Cast

iron,

alloy

steel, Not for titanium alloys, not for non ferrous alloys as the coated grades dont offer additional benefits over un coated.

stainless steel, super alloy

Ceramics

Cast iron, nickel base super Not for low speed operations alloys, non ferrous alloys, or interrupted cutting. Not for plastics machining Al, Ti alloys.

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TOOL GEOMETRY

Figure .tool geometry Tool geometry consists following parameters as -

Shank
The shank is the part of the tool that is held by the tool holder. It is the part of the tool that has no evidence of machining. The shank must be kept free of contamination, oxidation and scratching.

Cut diameter
This is the diameter or the width of the cut that the tool will produce.

Length of cut
This is the effective cutting depth of the tool or how deep the tool can cut into the material.

Flutes
This is the part of the tool that augers out the cut material. The number of flutes on a cutter is important in determining the chip load.

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WORK HOLDING
In order to machine a part on a CNC router the part must be held securely in place. This seems obvious; however, this is the one area that often causes major headaches. Another term used for part holding is fixturing. The hold-down system has a significant impact on part accuracy, quality of finish and on feed speeds and tooling life. Keep in mind that holding the part securely is important and there is no one system that will properly hold all parts. There are two fundamentally different types of parts that must be held in place. The first is a flat part or a sheet of material and the second is a three-dimensional object. The fixturing systems for each are similar; however, the three-dimensional part normally requires somewhat more complex arrangements. Some materials require higher cutting forces than others and these materials will require a more rigid hold-down system. Some materials will vibrate or chatter when cut.

Fig. Toggle clamp

Types of work holdingManual

The most cost effective way to hold down parts to a table is to screw, nail or to bolt the part to the work table. Other good methods of manually holding parts down are to glue the part down with regular or thermo fusible glue or with double sided tape. in the case where a prototype or a single piece will be cut, it might not be cost effective to build a holding fixture. For short production runs or for fixturing prototypes, another useful method is to use a toggle clamp. These come in many different configurations and sizes are easy to adjust and 13

to setup on a jig. One must be careful not to crash the tool or the spindle into the clamp when using this kind of device. it is always a good idea to test the program in a dry run at low speeds before putting such a fixture into production.

Vacuum
The most common system for holding down parts on the CNC router is conventional vacuum. Vacuum is simply the absence of air. the 45 km thick layer of air surrounding the earth weighs about 14 psi or 29.92" of mercury (hg) or 100 kilopascals (k pa) at sea level. This column of air pushes down equally on everything in all directions so that no resultant force is felt on the objects around us. When the air is removed from one side of an object, the air on the other side now pushes against the object with a force proportional to the absence of air on the opposite side. This is the basis of vacuum hold-down.the part to be machined is sealed against the tabletop or a fixture and then the air inside the seal is removed using a vacuum pump. The air on the outside then pushes the part against the fixture. The vacuum pressure is not the only thing holding the part against the table. Since lateral pressure is exerted by the cutter when it is machining the part, the coefficient of friction between the part and the fixture plays an important part as well. A perfect vacuum is not possible with current technology, no matter which kind of vacuum pump is used.

Types of Vacuum Work Holding Methods; a) Conventional vacuum fixturing

This method is mostly used in 5-axis production when trimming molded parts. Since these parts are almost never flat, special vacuum fixtures are made using plaster to conform to the part and a rubber seal is used around the vacuum ports.

b) Pod and rail

This vacuum cup type of hold-down is a widespread method of holding parts on a CNC machine. This is well indicated when one part at a time needs to be machined. There are many different configurations of pods for different applications and as it takes time to adjust the pods to different configurations and part sizes, this can be an inefficient way to work. Pod systems are not the universal solution that some manufacturers advertise.

c) Combination pod/flat table

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Table using conventional vacuum is often found. on lower-priced or older systems, a combination of pods on a flat rotary vane vacuum pumps are relatively inexpensive as they are small and are not required to pull a great volume of air. This system works well when there is a good seal with the part

d) High flow vacuum

This method is often associated with nested based systems. a sacrificial board otherwise known as a spoil board made particleboard sits atop a vacuum plenum on the worktable. Flow is so high that a low-pressure area is created on the surface. a flat part that is laid on this table will be held in place in this low-pressure area without the need for fixtures or seals.

e) Roller hold-down
Other methods of material holding have surfaced in response to specific industry needs. Roller hold-down systems are often seen in upholstery shops. This method isused to hold rough and often warped plywood that could not otherwise be held in place by a high flow vacuum.

Capacity of vacuum
The capacity for vacuum pumps is specified in a couple of different ways, depending on the type of vacuum pump and the manufacturer. It is important to know the scfm rating of the pump. It expresses the actual cubic feet per minute inlet capacity at a specific vacuum level. Capacities expressed in cfm or scfm (standard cubic feet per minute) can be very misleading because one has to take into consideration the volumetric efficiency of the pump at a specific vacuum level. Rotary vane pumps are generally rated in cfm of free air

displacement, which is the theoretical displacement at 0" hg vacuum. the requirements in vacuum flow or the capacity of the pump will be different whether vacuum cups, clamps or high flow universal vacuum tables are being used. A vacuum hold-down where the part rests on rubber seals may allow thepart to move or wiggle slightly on the soft seals.

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MATERIAL HANDLING
Manual material handling is often the norm in furniture and cabinet shops. This oversight is often at the expense of the manufacturer since the time spent loading and unloading machines often makes up most of the wasted time in a day. Often, CNC owners will try to trim seconds off a program or even try to run parts at much faster speeds. This will result in marginal savings in time and most often result in poor cut quality. Often they overlook parts and machine idleness and unnecessary material handling in their time analysis. Most of the efficiencies that can be gained at a CNC work stationary in handling material. Whether talking about the methods used to handle material or the strategies used to deal with material handling, large quantities of inventory or work in progress can usually be found all around the shop. Ensuring that raw material gets to the shipping door as a finished product in the best possible time will always have the greatest impact on a manufacturers bottom line.

Material handling equipment Scissor lifts

A simple scissor lift at the end of the worktable is often enough when mostly the same material is being processed all day. When more than one material is used, manufacturers often pre-stage lifts with the right combination of material so the operator can slide the right sheet on to the worktable. Care must always be taken when dragging sheet sacross each other as this can ruin the surface of the sheet below.

Vacuum lifts
Vacuum lifts are a little more expensive than a scissor lift but are also more versatile. They can pick up sheets from different piles around the CNC and give the added ability of removing larger parts from the work table once the machining is done .They are usually mounted on a crane bolted to the floor or wall. Some use high flow vacuum for both the holding and the lifting, while others use an electric winch for lifting and an air vacuum on a suction cup for holding.

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Automatic material handling

Automated material handling equipment is mostly found in very largeproduction plants.Automation can vary from a mechanized conveyorsystem to robotic arms doing most of the loading and unloading ofthe work.

AUTOMATIC TOOL CHANGER(ATC)

During the operation of a machine tool, considerable amount of time is spent in idle movement of tool such as tooling engagement and disengagement, tool change in tool setup. To improve the machine utilization, it is necessary to minimize these idle motions. To that extent automatic tool changers or ATC as is popular called, plays a very important role. These are particularly useful in machining operations where a number of tools are to be used for finishing the job. Though there are still some CNC machine tools which are sold ATC. For an ATC, it is necessary to have the following statementa) A tool magazine where sufficient number of tools can be stored. b) The tool adapter that has a provision for pick up by the tool change arm. c) The ability in the control to perform the tool change function. d) Tool change procedure.

Tool changing
In the case of turret the tool changing is relatively simple, because of the turret indexing. However in the case of other tool magazine, it is necessary to have a tool changing arm which can provide the necessary tool transfer. Generally the tool magazine is placed 17

closed to the spindle such that the actual tool transfer does consume a lot of time. Typically tool change time quoted by the various machine tools manufactured range from as low 2 to a maximum of 10 seconds. The tool change activity requires various motions.

Tool magazine
Tool magazine is to be used have to be considered in terms of following attributes; Storage capacity Type and shapes Tool change procedure

Storage capacity typically starts with about 12 and goes as high as 200 while 30-60 appears to be most common capacity of the tool magazines. The simplest type of tool magazine is a turret as shown in figure. The method combinations tool storage with the tool change procedure, without the need for a tool change arm. The turret simply indexes to bring the tool in the position of the machining. Since the spindle is combined with the tool turret as shown in figure. The main advantages of the system is that the tool is identifies directly with the pocket position and hence does not require a separate identification. Through it is a relatively simple method, the time taken for actual tool change is normally more except in the case of a tool in the adjacent pocket. Further the turret should have the capacity of indexing in both directions to minimize the change time. The next type of tool magazine is Drum or disc type magazine. The drum rotates for the purpose of tool change to bring the required tool to tool change arm and another type is chain type magazine.

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Operations of CNC
Straight Turning Drilling Step Turning Bearing Taper Turning Polishing Eccentric Turning Tapping Chamfering Parting 0ff Thread Cutting Reaming Facing Counter Boaring Spinning Under Cutting

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List of G-codes commonly found on Feeler CNC Machine:

Code

Description

G00

Rapid positioning

G01

Linear interpolation

G02

Circular interpolation, clockwise

G03

Circular interpolation, counterclockwise

G04

Dwell

G05P10000

High-precision contour control (HPCC)

G05.1 Q1.

Ai Nano contour control

G06.1

Non Uniform Rational B Spline Machining

G07

Imaginary axis designation

G09

Exact stop check

G10

Programmable data input

G11

Data write cancel

G12

Full-circle interpolation, clockwise

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G13

Full-circle interpolation, counterclockwise

G17

XY plane selection

G18

ZX plane selection

G19

YZ plane selection

G20

Programming ininches

G21

Programming inmillimeters (mm)

G28

Return to home position (machine zero, aka machine reference point)

G30

Return to secondary home position (machine zero, aka machine reference point)

G31

Skip function (used for probes and tool length measurement systems)

G32

Single-point threading, longhand style (if not using a cycle, e.g., G76)

G33

Constant-pitchthreading

G33

Single-point threading, longhand style (if not using a cycle, e.g., G76)

G34

Variable-pitch threading

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G40

Tool radius compensation off

G41 G42 G43 G44 G45 G46 G47 G48 G49 G50 G50 G50 G52 G53 G54 to G59 G54.1 P1 to P48 G70

Tool radius compensation left Tool radius compensation right Tool height offset compensation negative Tool height offset compensation positive Axis offset single increase Axis offset single decrease Axis offset double increase Axis offset double decrease Tool length offset compensation cancel Define the maximum spindle speed Scaling function cancel Position register (programming of vector from part zero to tool tip) Local coordinate system (LCS) Machine coordinate system Work coordinate systems (WCSs) Extended work coordinate systems Fixed cycle, multiple repetitive cycle, for finishing (including contours) Fixed cycle, multiple repetitive cycle, for roughing (Zaxis emphasis)

G71

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G72

Fixed cycle, multiple repetitive cycle, for roughing (Xaxis emphasis) Fixed cycle, multiple repetitive cycle, for roughing, with pattern repetition Peck drilling cycle for milling - high-speed (NO full retraction from pecks) Peck drilling cycle for turning Tapping cycle for milling, lefthand thread, M04 spindle direction Peck grooving cycle for turning Fine boring cycle for milling Threading cycle for turning, multiple repetitive cycle Cancel canned cycle Simple drilling cycle Drilling cycle with dwell Peck drilling cycle (full retraction from pecks) Tapping cycle,righthand thread,M03 spindle direction Tapping cycle, righthand thread,M03 spindle direction, rigid toolholder Absolute programming Fixed cycle, simple cycle, for roughing (Z-axis emphasis) Incremental programming Position register (programming of vector from part zero to tool tip) Threading cycle, simple cycle 23

G73

G73

G74 G74 G75 G76 G76 G80 G81 G82 G83 G84 G84.2

G90 G90 G91 G92

G92

G94 G94 G95 G96 G97 G98 G98 G99 G99

Feedrate per minute Fixed cycle, simple cycle, for roughing (X-axis emphasis) Feedrate per revolution Constant surface speed (CSS) Constant spindle speed Return to initial Z level in canned cycle Feedrate per minute (group type A) Return to R level in canned cycle Feedrate per revolution (group type A)

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List of M-codes commonly found on Filler CNC Machine :

Code

Description

M00

Compulsory stop

M01

Optional stop

M02

End of program

M03 M04 M05 M06 M07 M08 M09 M10 M11 M13 M19 M21 M21 M22

Spindle on (clockwise rotation) Spindle on (counterclockwise rotation) Spindle stop Automatic tool change (ATC) Coolant on (mist) Coolant on (flood) Coolant off Pallet clamp on Pallet clamp off Spindle on (clockwise rotation) and coolant on (flood) Spindle orientation Mirror, X-axis Tailstock forward Mirror, Y-axis

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M22 M23 M23 M24 M30 M41 M42 M43 M44 M48 M49 M52 M60 M98 M99

Tailstock backward Mirror OFF Thread gradual pullout ON Thread gradual pullout OFF End of program with return to program top Gear select - gear 1 Gear select - gear 2 Gear select - gear 3 Gear select - gear 4 Feedrate override allowed Feedrate override NOT allowed Unload Last tool from spindle Automatic pallet change (APC) Subprogram call Subprogram end

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BIBLIOGRAPHY
www.wikinpedia.org www.google.co.in (for images) www.himpson.in CTAE library

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