MANUFACTURING OF MOTOR BRACKET

An industrial training report submitted to the GITAM University in Partial fulfillment of

the requirements for the award of

FIVE YEAR DUAL DEGREE (B.Tech+M.Tech)

In

MECHANICAL ENGINEERING
By

INKOLLU VENKATA RANGA ADITYA -2230811114

N.J.V.UDAY BHASKAR

-2230811128

PEDDI VAMSI KRISHNA

-2230811134

S.N.V.SAI RAM

-2230811140

DEPARTMENTOFMECHANICALENGINEERING
GITAMSCHOOLOFTECHNOLOGY
GITAMUNIVERSITY
HYDERABAD
OCTOBER2014

GITAM UNIVERSITY
(Declared as Deemed to be University U/S 3 of UGC Act, 1956)

HYDERABAD CAMPUS

Department of Mechanical Engineering

CERTIFICATE
Certified that the Industrial Training report entitled INDUSTRIAL TRAINING AT
HMT PRAGA carried out by Mr. INKOLLU VENKATA RANGA ADITYA bearing
Roll No.2230811114, a student of VII Semester, IV year, in partial fulfillment for the
award of Five Year Dual Degree (B.Tech +M.Tech) in Mechanical Engineering at the
GITAM University, Hyderabad Campus during the academic year 2013-14. The project
report has been approved as it satisfies the academic requirements in respect of Industrial
Training prescribed for the said Degree.

Signature of the Faculty In-charge

Signature of the
HOD

Signature of the Examiner

1.
2.

GITAM UNIVERSITY
(Declared as Deemed to be University U/S 3 of UGC Act, 1956)

HYDERABAD CAMPUS

Department of Mechanical Engineering

CERTIFICATE
Certified that the Industrial Training report entitle INDUSTRIAL TRAINING AT HMT
PRAGA carried out by Mr. N.J.V.UDAY BHASKAR bearing Roll No.2230811128, a
student of VII Semester, IV year, in partial fulfillment for the award of Five Year Dual
Degree (B.Tech +M.Tech) in Mechanical Engineering at the GITAM University,
Hyderabad Campus during the academic year 2013-14. The project report has been
approved as it satisfies the academic requirements in respect of Industrial Training
prescribed for the said Degree.

Signature of the Faculty In-charge

Signature
of the HOD

Signature of the Examiner

1.
2.

GITAM UNIVERSITY
(Declared as Deemed to be University U/S 3 of UGC Act, 1956)

HYDERABAD CAMPUS

Department of Mechanical Engineering

CERTIFICATE
Certified that the Industrial Training report entitle INDUSTRIAL TRAINING AT HMT
PRAGA carried out by Mr. PEDDI VAMSI KRISHNA bearing Roll No.2230811134, a
student of VII Semester, IV year, in partial fulfillment for the award of Five Year Dual
Degree (B.Tech +M.Tech) in Mechanical Engineering at the GITAM University,
Hyderabad Campus during the academic year 2013-14. The project report has been
approved as it satisfies the academic requirements in respect of Industrial Training
prescribed for the said Degree.

Signature of the Faculty In-charge

Signature
of the HOD

Signature of the Examiner

1.
2.

GITAM UNIVERSITY
(Declared as Deemed to be University U/S 3 of UGC Act, 1956)

HYDERABAD CAMPUS

Department of Mechanical Engineering

CERTIFICATE

Certified that the Industrial Training report entitle INDUSTRIAL TRAINING AT HMT
PRAGA carried out by Mr. S.N.V.SAI RAM bearing Roll No.2230811140, a student of
VII Semester, IV year, in partial fulfillment for the award of Five Year Dual Degree
(B.Tech +M.Tech) in Mechanical Engineering at the GITAM University, Hyderabad
Campus during the academic year 2013-14. The project report has been approved as it
satisfies the academic requirements in respect of Industrial Training prescribed for the
said Degree.

Signature of the Faculty In-charge

Signature
of the HOD

Signature of the Examiner

1.
2.

ACKNOWLEDGEMENT
The project entitled INDUSTRIAL TRAINING AT HMT PRAGA is the sum of total
of my effort. It is my duty to bring forward to each and every one who is directly or
indirectly in relation with our project and without whom it would not have gained a
structure.
I express our sincere thanks to the HEAD OF THE DEPARTMENT
Dr. P.ESHWARAYA of GITAM UNIVERSITY HYDERABAD CAMPUS for allowing
us to carry out our industrial training and for his continuous support and encouragement
during this course
We express our sincere gratitude to SRI.N.V.S.RAMCHANDRA
RAO,
Deputy Manager, small parts (Production MT-2 shop) for sending his valuble time and
suggestions and guidance made by him at various stages of his work done at HMT
MACHINE TOOLS LTD, PRAGA DIVISION.

Finally we sincerely thank to all members who are helpful directly in the
completion of our project. Our heartfelt thanks to all the employees, who spent their
valuable time during our training sessions in explaining all the intricacies involved in the
system process and being so patient in answering all queries.

ABSTRACT
Manufacturing of Motor bracket through CNC machine is less time
consuming and gives better efficiency and finishing when compared to
the general manufactuing process.

COMPANY PROFILE
HMT Machine Tools PRAGA Division is one of the
leading machine tool manufacturing units in India. Establishment in
1943, pragas products are well known in the field of machine tools.
The company is organised in two divisions-viz the machine tool and
CNC division which pulsates with the activities of employees, turning
out a wide range of products. The two divisions equipped with modern
facilities of design, development and manufacturing tools, are manned
by qualified personnel with proven record of technical knowledge and
exquisite craftsmanship acquired over a period of years.
MANUFACTURES :
Surface Grinding Machines.
Cutter &Tool Grinding Machines.
Thread Rolling Machines.
Spline Rolling Machines.
Pulley Forming Machines.
Tube finishing machines.
Milling machines.
Horizontal machining centres.
CNC Lathe machines.
CNC Milling machines.
CNC Surface grinding machines.
CNC Cutter &Tool grinding machines.
Praga are also manufactures of customer tooling for the above
machinery like:
Jigs and Fixtures

 Mountings.
Accessories.
Tooling for the above mentioned cold forming process.
Praga is collaborated with some of the world famous
companies like Jones & shipman of U.K., Gambin of France, Escoffier of
France, George Fischer of Switzerland, Mitsubishi Heavy industries
Japan and Keiyo Seiki also of Japan. The collaborations have culminated
in Praga producing machine tools of the highest quality conforming to
international standards.
In the companies of the directives of the Govt. of India
actions have been initiated for the merger of Praga tools limited with
HMT limited. Bangalore obtaining of necessary approvals and sanctions
of BIFR and Government of India with the effect from (13-06-2008) and
all formalities completed on (20-06-2009) Praga tools limited renamed
as m/s HMT Machine Tools Limited VI (Praga division hyd) from this
data all the guidelines and policies, rules and regulations and facilities
are applicable to the Praga employees as per HMT Machine Tools
Limited.
LEADING MANUFACTURERS OF:
Surface grinding machines
Cutter and tool grinding machines (CTG)
Thread rolling machines
Plano milling machines
Pulley forming machines
Drilling machines
Milling machines
Horizontal machining centers
CNC lathe machines
CNC milling machines
CNC surface grinding machines
CNC cutter and tool grinding machines
Praga is also manufacturer of customer tooling for the above

machinery like:
Jigs and fixtures
Mountings
Accessories
Tooling for the above mentioned cold forming processes
Praga has collaborations with some of the world famous
companies like Jones & Shipman of U.K, Gambian of France, Escoffier of
France, George Fisher of Switzerland, Mitsubishi Heavy industries and
Keiyo Seiki of japan. The collaborations have culminated in Praga
producing machine tools of the highest quality confirming to
international standards.
Praga has contributed to the development of machine tool industry
in the country and created a vast band of skilled technicians. Thus
Praga, today, is a name of reckon within the machine tool industry.
PRESENT STATUS OF THE COMPANY:
The government of India on the recommendation of Board for
Industrial and Financial Reconstruction (BIFR) issued a notification by
merging PRAGA TOOLS LTD. With the HMT Machine Tools ltd. With
effect in 13-06-08. All formalities completed on 20-06-09. PRAGA
TOOLS became the part of and forced under HMT machine tools Ltd.
Treated on of the unit and made HMT MACHINE TOOLS LTD. PRAGA
DIVISION. From the above date onwards PRAGA TOOLS Ltd. Following
rules and regulations as per to the HMT Ltd.
CHAPTER: 1

INTRODUCTION

CNC machining is short for computer numerical control

machining. It refers to computer controller that reads the code and
instructions and drives a machining tool in order to make a product
according to the specific requirements.
CNC machine is a tool or a device that is critical to an industrial

system. It is used to aid the design and the manufacturing of a

product. These CNC machines are programmable to meet the specific
requirements of users. CNC machining allow manufacturers to do curve
cuts as easy as straight cuts. Three dimensional structures were also
as easy to build with the introduction of CNC into the machinery.
Aside from the ease of use that CNC machining has given to its
users, the consistency and the quality of the output has also been
improved. With this technology, the likelihood of errors has been
dramatically reduced. The amount of time spent on rework has been
reduced as well. The final output through this kind of process is done in
a very efficient manner.
CHAPTER: 1.1
BENEFITS OF CNC:
COST SAVINGS: CNC machining allows the operator to take full
advantage of raw materials. With the accuracy delivered through
CNC machining, waste is decreased which minimizes loss and
increases profit over costs.
SPEED: CNC machines can quickly produce parts that would
normally take multiple steps to manufacture otherwise
SAFETY: Because the entire fabrication process is automated,
the operator is kept out of harms way, allowing for a much safer
work environment.
IMPROVED EFFICIENCY: CNC machines are the most efficient
means of creating a component due to the fact that most feature
internal quality assurance detectors.
With the efficiency of CNC machining in addition to its speed of
production and optimum raw material usage, its easy to see why
CNC machining is the gold standard of metalworking and part
fabrication.
CHAPTER: 1.2
DIFFERENCE BETWEEN GENERAL AND CNC MACHINES
GENERAL MACHINES

CNC MACHINES

Cycle time is more

Run by operator
Floor to floor time is more
Human errors and design
modifications are difficult
Occupies less space
Human involvement is more

Cycle time is more

Run by paper tape
Floor to floor time is less
Flexible modifications and
editing are possible
Occupies less space
Human involvement is less

CHAPTER: 1.3
ADVANTAGES OF CNC MACHINES
CNC offers the following advantages in manufacturing:
Higher flexibility and reduced lead time
Increased productivity and consistent quality
Reliable operation
Reduced man power
Higher accuracy and shorter cycle time
Automatic material handling
Can store programs easily
CHAPTER: 2
CNC MACHINING CENTRES
CNC machining centers, which are used to machine stationary
work pieces with rotating cutting tools are among the most popular
types of metal cutting machine tools in existence today.
CHAPTER: 2.1
Types of CNC machining centres:

 Vertical machining centre

Horizontal machining centre
In the vertical machining centre, the spindle axis is vertically oriented.
Milling cutters are held in the spindle and rotate on its axis. The spindle
can generally be extended (or the table can be raised or lowered,
giving the same effect), allowing plunge cuts and drilling.
A horizontal mill has the same sort of x-y table, but the cutters
are mounted on the horizontal arbor across the table. Many horizontal
mills also feature a built in rotary table that allows milling at various
angles, this feature is called a universal table.
Both the VMC and HMC being versatile, which can hold many
tables in their tool magazines using each one for different purpose it is
the HMC holding the upper hand in machining cubical component like
valve block. They prove to be advantageous in reducing the number of
job setups required and there by considerably minimizing the overall
setup time.
CHAPTER: 2.2
Fundamentals of CNC machine programming
These are some of the fundamentals we come across during CNC
machine programming.
CHAPTER: 2.2.1
Types of interpolations
There are three types of interpolations we see during CNC
programming. They are linear interpolation (G01), clock wise
interpolation (G02) and counter clock wise interpolation (G03).
CHAPTER: 2.2.2
Types of work piece
There are two types of work pieces in general. They are punch
(male or shaft) and die (female or hole). By using the above two

circular interpolations and by giving compensation directions, we

can generate either punch or die as a result.
PROGRAM

COMPENSATION
DIRECTION

RESULT

Clockwise

Right side (G42)

Die

Clockwise

Left side (G41)

Punch

Counter clock wise

Right side (G42)

Punch

Counter clock wise

Left side (G41)

Die

CHAPTER: 2.3
Co-ordinate systems
CHAPTER: 2.3.1
Cartesian co-ordinate system
In this system we use the values of X, Y and Z. In this, two
types of programming can be made. One is absolute
programming in which every point value will be given with
respect to origin and the other is of incremental
programming in which the value of a point is given with
respect to previous point.
CHAPTER: 2.3.2
Polar coordinate system:
In this system, the length and angle of a point w.r.t the previous
point are taken in consideration to determine a point.
Co-ordinate axes
Linear axes

Rotary axes

Circular interpolation
parameters

CHAPTER: 2.4
Numeric control (NC) codes
There are two types numeric control codes namely G-codes and
M-codes. G-codes are preparatory functions used for determining
the geometry of the work piece. M-codes are miscellaneous
functions used for controlling the machine.
CHAPTER: 2.5
Orientations of axes.
fig: 1
Orientation of axes is based on Flemings right hand rule.
Z axis always the spindle axis and the X, Y axes are spindle
faces for any machine component.
The values of X, Y, Z displayed in the monitor are the
values of the point of intersection of spindle face and axis.
CHAPTER: 2.6
Cutter compensation (G40, G41, G42)
The collection of G4, G41 and G42 codes allow the machine
controller to produce very accurate arcs andtapers on the billet, by
compensating for the toolradius.Complex work piece shapes are
therefore programmedwith cutter compensation mode active. The
radius ofthe tool (the offset amount) is measured, thenentered into the
offset file in the machine controller.Once set, the tool path can be
offset by this value,regardless of the program.
G40

Cancel

movement along programmed path

G41

Left hand side

G42

Right hand side

movement on the left hand side of the

programmed path
movement on the right hand side of the
programmed path

G41: left hand compensation

fig: 2
G42: Right hand compensation
CHAPTER: 2.7
Offset
Offsets are generally of two types
Work offset
It is to define the reference point on the work piece w.r.t
the home position X0, Y0, Z0
Tool offset
The distance between the spindle face and the tip of the
cutting tool.
CHAPTER: 2.8
Register
CHAPTER:2.8.1
Format of work offset register.
The format of registers will not differ from one CNC system
to other system. We can store the offsets from register G54
to G59 and G501 to G599 in Sinumerik and Fanuc systems.

G54

G55

G56

CHAPTER:2.8.2
Format of tool offset registers

Length 1
T1

Radius/diamet
er
-

T2

T3

It is the distance between the spindle face and tip of the

cutting tool.
T code

H code

D code

0001

0002

0003

CHAPTER: 3
Machine control units
Various types of MCUs are available in the market. Some of them
are
SINUMERIK/HINUMERIK
FANUC
GE
MARK++
FOGOR
GE-FANUC
CHAPTER: 4
CNC PROGRAMMING PARAMETERS
The various parameters that are used in writing a CNC program for a
certain job are:
CHAPTER: 4.1
Sequence number (N-Word)
This number is used to identify the block of instructions. One to
four digits are used to denote ta sequence number.

Example: N 0001, N 0002

CHAPTER: 4.2
Alphabetical symbols used in NC code files
These are the alphabetical symbols that are used in NC- codes.
Bold ones below are the letters seen most frequently throughout
the program.
CHAPTER: 4.3
Preparatory codes (G codes)
G codes are also called the preparatory codes, and are any word
of CNC program that begins with letter G. Generally it is a code
telling the machine tool what type of action to perform. It
consists of two numerical digits followed by G word.
List of G-Codes commonly found on FANUC and similarly
designed controls:
CODE
G00

DESCRIPTION
Rapid positioning

COROLLARY INFO
The G00 code executes a non-cutting
movement, at arapid feedrate, to a
specific co-ordinate position in theworking
area (operating under absolute coordinate
movement) or when a certain distance
from
apreviouslystated position (under
incremental coordinateMovement) is
programmed.

G01

Linear
interpolation

The G1 code executes a cutting

movement following a straight line, at a
set feed rate.
The feed rate value programmed into the
G1 command is the actual feed rate
along the proposed tool path, not the feed
rate of each axis/slide. On single axis
moves (i.e., the tool moves exactly
parallel to the X, Y or Z axis direction), the
slide will feed at the rate stated in the
G1 command. On two or three axis
moves (i.e., the tool is moving in a
straight diagonal line), all the slides have
to operate exactly the same length of
time, in order to produce a singlediagonal
(vector) move. The machine controller will
calculate the separate feed rates for the
X, Y and Z slides, enabling the actual
vector feed rate to
equal

that stated in the G01 command.

G02 and
G03

Circular
interpolation,
clockwise and
anti-clock wise
respectively.

G04

Dwell

G05

High precision
contour control

G05.1

Ai Nano contour
control

G06.1

Non uniform
rational B spline
machining

The G2 code executes a cutting

movementfollowing a clockwise circular
path, at a setfeedrate.
The G3 code executes a cutting
movementfollowing a counterclockwise
circular path, at a setfeedrate.
The definitions of clockwise (G2)
andcounterclockwise (G3) are fixed
according to
thesystem of co-ordinates in the diagram
below.
When programming arcs using absolute
values (G9),the X and Y values describe
the end point of the arc,in relation to the
datum position of the workpiece. Thearc
end point is sometimes referred to as the
targetposition.
When programming arcs using
incremental values(G91), the X and Y
values relate to the distance movedalong
the X and Y axes, from the start point of
the arcto the end point of the arc. The
sign of the X and Yaxis moves (+/-) will
depend on the movement of themachine
slides in relation to their start position.
There are four ways to program a
clockwise circular
path using the G02 and G03 code:
G9 G2 X _ _ _ _ Y _ _ _ _ R _ _ _ F _ _ _ ;
G9 G2 X _ _ _ _ Y _ _ _ _ I _ _ _ J _ _ _ F _
__;
G91 G2 X _ _ _ _ Y _ _ _ _ R _ _ _ _ F _ _ _
_;
G91 G2 X _ _ _ _ Y _ _ _ _ I _ _ _ J _ _ _ F _
__;
Takes an address for dwell period (may be
X, U or P). the dwell period is specified in
milliseconds
Uses a deep look-ahead buffer and
simulation processing to provide better
axis movement acceleration and
deceleration during contour milling.
Uses a deep look-ahead buffer and
simulation processing to provide better
axis movement acceleration and
deceleration during contour milling.
Activates non uniform rational B spline
complex curve and waveform machining.

G07
G09
G10
G11
G12

Imaginary axis
designation
Exact stop check
Programmable
data input
Data write cancel
Full circle
interpolation.
clock wise

Fixed cycle for ease of programming 360

circular interpolation with blend radius
lead in lead out. Not standard in Fanuc
controls
Fixed cycle for ease of programming 360
circular interpolation with blend radius
lead in lead out. Not standard in Fanuc
controls

G13

Full circle
interpolation,
counter clockwise

G17
G18
G19
G20

XY plane selection
ZX plane selection
YZ plane selection
Programming in
Somewhat uncommon except in USA and
inches
Canada and UK. However, in the global
marketplace, competence with both G20
and G21 always stands some chance of
being necessary at any time. The
minimum increment in G20 is one ten
thousandth of an inch, which is a larger
distance than the usual minimum
increment in G21. The physical difference
sometimes favors G21 programming.
Programming in
Prevalent worldwide. However in the
millimeters
global marketplace, competence with
both G20 and G21 always stand some
chance of being necessary at any time.
Return to home
Takes X Y Z addresses which define the
position
intermediate point that the tool tip will
pass through on its way home to machine
zero. They are in terms of part zero, no
machine zero
Return to
Takes a P address specifying which
secondary home
machine zero point desired, if the
position
machine has several secondary points.
Takes X Y Z addresses which define the
intermediate point that the tool tip will
pass through on its way home to machine
zero. They are in terms of part zero.
Skip function
Single point
Similar to G01 linear interpolation, except
threading, long
with automatic spindle synchronization for

G21

G28

G30

G31
G32

G33
G34
G40
G41

hand style
Constant pitch
threading
Variable pitch
threading
Tool radius
compensation off
Tool radius
compensation left

G42

Tool radius
compensation
right

G43

Tool height offset

compensation
negative

G44

Tool height offset

compensation
positive

G45

Axis offset single

increase
Axis offset single
decrease
Axis offset double
increase

G46
G47

single point threading

MILLING: given right hand helix cutter and

M03 spindle direction, G41 corresponds to
climb milling. Takes an address that calls
an offset register value for radius.
TURNING: often needs no D or H address
on lathes, because whatever tool is active
automatically calls its geometry offsets
with it.
G41 and G42 for milling have become less
frequently used since CAM programming
has become more common. CAM systems
allow the user to program as if with zero
diameter cutter. The fundamental concept
of cutter compensation is still in play, but
the programming mindset is different. The
human does not choreograph the tool
path with conscious. Because the CAM
software takes care of it.
Similar corollary info as for G41 given
right hand helix cutter and M03 spindle
direction, G42 corresponds to
conventional milling
Take an address, usually H, to call the tool
length offset register value. The value is
negative because it will be added to
gauge line position. G43 is the commonly
used version
Take an address, usually H, to call the tool
length offset register value. The value is
positive because it will be subtracted to
gauge line position. G43 is the commonly
used version

G48
G49
G50

G51

G52
G53
G54 to
G59

G54.1
P1 to
P48
G70

G71

Axis offset single

decrease
Tool length offset
compensation
cancel
Define maximum
spindle speed

Cancels G43 or G44

Takes an S address integer which is

interpret as rpm. Without this feature G96
mode would revolute the spindle to wide
open throttle when closely approaching
the axis of rotation
Position
Position register is one of the original
register(program
methods to relate the part coordinate
ming of vector
system to the tool position, which
from part zero to
indirectly relates it to the machine cotool tip)
ordinate system, the only position the
control really knows. Not commonly
programmed anymore because G54 to
G59 are a better, newer method. Called
via G50 for turning, G92 for milling. Those
G addresses also have alternate
meanings. Position register can still be
useful for datum shift programming.
Local coordinate
Temporarily shifts program zero to new
system
location. This simplifies programming in
some cases
Machine
Takes absolute coordinates with reference
coordinate system to machine zero rather than program zero
Work coordinate
Have largely replaced position register
systems
(G50 and G92). Each tuple of axes offsets
relates program zero directly to machine
zero. Standard is 6 addresses with
optional extensibility to 48 via G54.1 P1
to P48
Extended work
Up to 48 more WCSs besides the 6
provided as standard
Coordinate
By G54 to G59. Note floating point
systems
extension of G code data type. Other
examples have also evolved. Modern
controls have the hardware to handle it
Fixed cycle,
multiple repetitive
cycle, for
finishing(including
contours)
Fixed cycle,
multiple repetitive

G72

G73

G73

G74
G74

G75
G76
G76

G80
G81
G82

cycle, for
roughing
(including
contours) Z axis
emphasis
Fixed cycle,
multiple repetitive
cycle, for
roughing(includin
g contours) X axis
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 for
drilling
Tapping cycle for
milling, left hand
thread, and 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

G83

Peck drilling cycle

G84

Tapping cycle,
right hand thread,

Retracts only as far as a clearance

increment. For when chip breaking is the
main concern, but chip clogging of flutes
is not

No dwell built in
Dwells at thehole bottom for the number
of milliseconds specified by the P address.
Good for when hole bottom finish matters
Returns to R level after each peck. Good
for clearing flutes of chips

G84.2

G90
G90

G91
G92

G92
G94
G94

G95
G96

M03 spindle
direction
Tapping cycle,
right hand thread,
M03 spindle
direction, rigid
tool holder
Absolute
programming
Fixed cycle,
simple cycle, for
roughing ( Z axis
emphasis)
Incremental
programming
Position
register(program
ming of vector
from part zero to
tool tip)
Threading cycle,
simple cycle
Feed rate per
minute
Fixed cycle,
simple cycle, for
roughing (X axis
emphasis)
Feed rate per
revolution
Constant surface
speed

G97

Constant spindle
speed

G98

Return to initial Z
level in canned
cycle
Feed rate per
minute
Return to R level
in canned cycle

G98
G99

When not serving for absolute

programming

On group A lathes, feed rate per minute is

G98
When not serving for feed rate per minute

On group A lathes, Feed rate per

revolution is G99
Varies spindle speed automatically to
achieve a constant surface speed. See
speeds and feeds. Takes an S address
integer, which is interpreted as sfm in
G20 mode or as m/min in G21 mode
Takes an S integer, which is interpreted as
rev/min (rpm). The default speed mode
per system parameter if no program is
programmed

Feed rate per minute is G94 on group

type B

G99

Feed rate per

revolution

Feed rate per revolution is G95 on group

type B

CHAPTER: 5
Co-ordinates (X,Y and Z word)
Co-ordinates give the position of the tool over and across the job.
X, Y and Z-words are used in the three axes system and can be
specified in inches or mm. for incremental mode of X, Y and Z
directions U, V and W are used. A, B and C-words are used for
rotational axes X, Y and Z directions respectively.
CHAPTER: 5.1
Feed rate (F-word)
In machining operations, this word specifies the feed rate, feed
per minute or per revolution in inches or millimeters.
CHAPTER: 5.2
Spindle speed(S-word)
This S word specifies the rate at which the spindle has to rotate.
It is expressed in revolutions per minute.
CHAPTER:5.3
Tool selection(T-word)
This T word specifies which tool is to be used for operation
among several tools in the tool magazines.
CHAPTER:5.4
Miscellaneous code(M-word)
These codes are also called as auxiliary codes used to specify the
machine functions which are available on the machine tool.
These codes give command to the machine to work.
CHAPTER: 5.5
LIST OF M-CODES MOST COMMONLY FOUND ON FANUC
AND SIMILARLY DESIGNED CONTROLS

CODE
M00

DESCRIPTION
Programmed stop unconditional

M01
M02
M03
M04
M05
M06
M07
M08
M09
M10
M11
M12
M13
M17
M18
M19
M20
M21
M22
M30
M47
M48
M49
M51
M56
M57
M60
M61
M62
M63
M64
M65
M80
M83
M98
M99
M66
M67
M68
M69
M70
M71
M72
M73

Optional stop
End of program
Spindle clockwise
Spindle counter clockwise
Spindle stop
Tool change
Mist coolant on
Flooded coolant on
Coolant off
Table clamp (B-Axis)
Table unclamp (B-Axis)
Custom macro interrupt on
Air blow on
Custom macro interrupt off
Magazine index
Spindle orientation
Tool number set for ready
Tool number set for spindle
ATC special cycle mode select
End of program and type rewind
Toll breakage check
Override on
Override off
Oil hole contact on
Sensor air blow on
Sensor air blow off
Pallet change
A B program select (next pallet B side)
A B program select (next pallet A side)
Pallet unloading
Pallet loading
Pallet change finished
Pallet magazine index
Pallet loading (unmanned CAR)
Pallet unloading (unmanned CAR)
Calling of sub program
End of sub program
Magazine tool unlock magazine cover
Magazine tool lock, magazine cover close
Spindle tool eject
Spindle tool lock
Changer arm spindle side
Changer arm magazine side
Changer arm advance
Changer arm retract

M74
M75
M76
M77
M78
M79
M84
M85
M86
M87
M88
M89
M90
M91
M92
M93
M94
M95
M96
M97

Changer arm rotate clock wise

Changer arm rotate counter clock wise
Relay pot retract
Relay pot advance
Relay pot magazine side
Relay pot spindle side
Pallet wedge out
Pallet wedge in
Table index position
Table clamp
Table clamp in
Table clamp out
Pallet AWC position
Pallet middle position
Splash cover open
Splash cover close
Index roller out
Index roller in
Pallet roller advance
Pallet roller retract

CHAPTER: 5.6
End of block (EOB)
This is to identify the end of the instructions in a block. Every
block is ended by the EOB word.

Example: N----G----X----Y----Z----M----H----;

CHAPTER: 6
TYPICAL PROGRAMMING PROCEDURE
WHAT IS PART PROGRAMMING?
A program is a set of encoded information giving co-ordinate
values and other details to indicate how a tool should be moved
in relation to the work piece in order to achieve a desired
machining form.
A part program contains all the information to machine a
component, which is input to the CNC system. The CNC system
provides signals at correct time and correct sequence to the

various drive units of the machine.

CHAPTER: 6.1
PROGRAM PLANNING
The development of any CNC program begins with a very
carefully planned process. Such a process starts with the
engineering drawing of the required job for production. Before
the part is machined, several steps have to be considered and
carefully evaluated.
These are the following steps that are considered while
developing a CNC program.
Study of initial information
Machine tool specifications
Control system features
Sequence of operations
Setup of the part
Technological data (speed, feed rate)
Determination of tool path
Program writing and transfer to CNC
Program testing and debugging
Initial information
For programming, a good knowledge of material such as
size, shape, hardness, etc., are essential. The drawing and
the material are the primary information about the
required part. At this point, CNC program can be planned.
The objective of such a plan is to use the initial information
and establish the most efficient way of machining with all
related considerations mainly part accuracy, productivity,
safety and convenience.
CHAPTER: 6.2
Machine tool features
During program planning, programmer should concentrate
on usage of particular machine tool and CNC system.

CHAPTER: 6.3
Machine type and size
Each part has to be set up in a fixture and the CNC
machine should be large enough to handle the size of the
part and the part should not be heavier than the maximum
allowed weight. Other features such as the machine power
rating, spindle speed, feed rate range, number of tool
changes, tool changing systems are also of equal
importance.
CHAPTER:6.4
Control system
The control system is the heart of the CNC system. Being
familiar with the standard and optional features available
on all controls is must. This allows usage of variety of
advanced programming methods such as machining
cycles, sub programs.
CHAPTER: 6.5
Machining sequence
The basic approach for determining the machining
sequence is the evaluation of related operation. In general,
program should not be planned in such a way that the
cutting tool once selected should do as much work possible
before a tool change.
CHAPTER:6.6
Part setup
Part set-up deals with:
How to mount the raw or pre machined material
What supporting tools and devices should be used
How many operations are required to complete as
many machining sequences as possible
CHAPTER: 6.7
Technological decisions
The size of the cutter and type of material will influence
speeds and feeds. The power rating of the machine tools
helps to determine what amount of material can be

removed easily.
CHAPTER: 6.8
Tool path
This process involves individual cutter movements in its
relationship to the part. The key factor for understanding
this principle is to visualize the tool motion but not the
machine motion.
CHAPTER: 6.9
Manual programming
The CNC controls made the manual programming much
easier than ever before by using fixed or repetitive
machined cycles, variable type programming, standard
mathematical input and other time saving features.
CHAPTER: 6.10
Responsibilities of a CNC operator
Job loading and setting as per job layout, entering
the program manually, loading the required cutting
tools as per the layout and fixing the work-zero with
respect to machine zero
Verification of program from graphic simulation and
machining the job in single mode as per the program
and inspection of its dimension.
Optimization of program.
CHAPTER: 7
MOTION CONTROL SYSTEMS
In order to accomplish the machining processes, the tool
and work piece must move relative to each other. There
are three basic types of motion control system.
Point to point
Straight cut
Contouring
CHAPTER: 7.1
Point to point
Point to point is also called as positioning system. In this,

the objective of the machine tool control system is to move

the tool to a predefined location. The path by which this
movement is accomplished is not important. Once the tool
reaches the desired position, the machining operation is
performed at that position. Drilling operation and spot
welding in certain operations are done by this system.
CHAPTER: 7.2
Straight cut:
Straight cut control systems are capable of moving tool
parallel to one of the major axes at a controlled rate
suitable for machining. It is therefore appropriate for
performing milling operations to fabricate work pieces of
rectangular configurations. With this type of NC systems it
is not possible to combine movements in more than single
axis direction. Therefore angular cuts on the work piece
would not be possible. An NC machine tool capable of
performing straight cut movements is also capable of point
to point movements.
CHAPTER: 7.3
Contouring control
A contouring control can exactly move at least 2
(mostly 3) or more axes relative to each other,
meaning it can move the tool on any straight line
or circular arc through space. The control
interpolates the contouring motion by
calculating the feed path as a series of
sequential points,
Leading the individual axes at the appropriate
speeds so that the motion remains within the
permissible tolerance range for the prescribed
line or curve and bringing all axes together
simultaneously at the programmed end position.
A counter control can execute tool motions in a
plane or in space for work piece machining. It is
used, for example. On milling machines, lathes,
electrical discharge machines and machining
centers.
CHAPTER:8
AUTOMATIC TOOL CHANGING ARM

The automatic tool changing cycle involves using single or

double grippers. A direct exchange of tools from the magazine to the
spindle can take place without additional exchange arms and although
this process is simplest in design, it takes great amount of time. A
typical tool changing process consists of the following processes
Locate the next tool to be used in the magazine
Remove the used tool from the spindle
Insert the new tool in the spindle
Return the used tool back into magazine
CHAPTER: 8.1
WORK CHANGERS
Machine tool down time due to aligning, clamping, loading and
unloading of work pieces can be avoided by automatic work piece
changing equipment.
Generally, pallet changing systems are used, pallet being work
storing platforms which provide special seating faces and other
features to allow for accurate location and clamping to work holding
surfaces of the machine tool.
CNC PROGRAM FOR MOTOR BRACKET AS SHOWN IN THE
DRAWING:
O 1306 (3413C07)
B180;
M100;
N10 T1;
M6;
G00 G90 G54 X0.0 Y0.0;
G00 Z100.00 G43 H186;
M3 S350;
(70 T0 106BB);
G98 G81 R5.0 Z-40.0 F10;
M5;
M100;
N20 M6;
G00 G90 G54 X0.0 Y0.0;
G0 Z100.0 G43 H156;

M3 S350;
(107BB);
G98 G76 R5 Z-40 I0.2 F10;
M5;
M100;
N30 M6;
G00 G90 G54 X0.0 Y0.0;
G00 Z100 G43 H144;
M3 S350;
(108H7BB);
G98 G81 R5 Z-35 F10;
N40 M6;
G00 G90 G54 X0.0 Y0.0;
G00 Z100 G43 H1;
M3 S1000;
(C DRILL);
G98 G81 X-82.5 Y-90.0 R5.0 Z-8.0 F50;
X82.5;
Y-30.0;
X-82.5;
Y-60.0;
X82.5;
M5;
M100;
N50 M6;
G00 G90 G54 X0.0 Y0.0;
G0 Z100.0 G43 M125;
M3 S650;
(13d);
G90 G83 X-82.5 Y-90.0 R5.0 Z-40.0 Q10.0;
F30;
X82.5;
Y-30.0;
X-82.5;
M5;
M100;
N60 M6;
N70 M00;
B0;
N80 T8;
G00 G90 G55 X0.0 Y0.0;
G00 Z100 G43 H55;
M3 S500;
(38UD);
G98 G81 R5.0 Z-30.0 F20;
M5;
M100;
N90 M6;
G00 G90 G55 X0.0 Y0.0;
G0 Z100 G43 M64;
M3 S500;
(44BB);
G98 G81 R5 Z-30.0 F10;
M5;

M100;
N100 M6;
G0 G90 G55 X0.0 Y0.0;
G00 Z100.0 G43 H66;
M3 S500;
(54BB);
G98 G81 R5.0 Z-30.0 F10;
M5;
M100;
N110 M6;
G00 G90 G55 X0.0 Y0.0;
G00 Z100 G43 H72;
M3 S500;
(65BB);
G98 G81 R5.0 Z-30 F10;
M5;
M100;
N120 M6;
G00 G90 G55 X0.0 Y0.0;
G00 Z100 G43 H3;
M3 S400;
(75BB);
G98 G76 R5.0 Z-30.0 I0.2 F10;
M5;
M100;
N130 M6;
G00 G90 G55 X0.0 Y0.0;
G0 Z100.0 G43 H104;
M03 S450;
(109 25EM);
G00 Z5.0;
G01 Z-7.3 F25;
X42.0;
G02 I-42.0;
G01 X0.0 Y0.0 F500;
G00 Z100;
M5;
M100;
N140 M6;
G00 G90 G55 X0.0 Y0.0;
G00 Z100 G43 H48;
M3 S350;
(110H7 BB);
G98 G76 R5.0 Z-7.2 I0.2 F10;
M5;
M100;
N150 M06;
M5;
M100;
N160 T1;
M6;
G00 G902 G55 X0.0 Y0.0;
G00 Z100 G43 H1;
M3 S1000;

T2;
(C DRILL);
G17 G90 G16;
G98 G81 X65 Y45 R5.0 Z-705 F100;
Y135.0;
Y225.0;
Y315.0;
G80 G15;
M100;
N170 M6;
G00 G90 G55 X0.0 Y0.0;
G00 Z100 G43 H74;
M3 S650;
T3;
(6.5 DRILL M8_;
G17 G90 G16;
G98 G81 X65.0 Y45.0 R5.0 Z-30.0 F30;
Y135;
Y225;
Y315;
G80 G15;
M100;
N180 M6;
G00 G90 G55 X0.0 Y0.0;
G00 Z100.0 G43 H55;
M03 S500;
G93 G81 R5.0 Z-30 F25;
M100;
N190 M6;
;
M30;
%
%
%
fig: 3 (MOTOR BRACKET)

CONCLUSION
In this project, a comparison of the total time estimation between
general and CNC machining processes has been done. We observed
that this comparison proves that Motor bracket when manufactured on
CNC machining center takes comparatively less time than the general
machining processes. The CNC machine also gives us the better results
like higher accuracies, consistence and reputability or in a way, higher
productivity.

BIBLIOGRAPHY
Workshop technology

by V.N Kumar

 Production Technology by R.K Jain

Workshop technology
WEBSITES:
www.cnc.com
www.pragatools.com

www.wikipedia.com
Cnc machinists.com

by Hajra Chowdary