DUTY : 02.

00 PERFORM CNC MILLING OPERATION

TASK : 02.01 Conduct Daily Inspection on CNC Milling Machine

SOALAN 1

Berdasarkan kepada gambarajah di bawah (Rajah 1), namakan bahagian-bahagian utama Mesin
CNC Milling.

No Nama Bahagian
.
1 Main cooling device
2 ATC (Automatic Tool Change)
3 Head
4 Main operation panel
5 Table
6 Bed
7 Coolant tank
8 ATC operation panel
9 Tool changing window
10 Column
11 Saddle

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SOALAN 2

Namakan dan terangkan Fungsi setiap button yang terdapat pada Main Operation Box (1) dan
Main Operation box (2) pada mesin CNC Milling.

Main Operation Box (1)

Main Operation Box (2)

Fungsi setiap button pada Main Operation Box (1)

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NO NAME
1 Mode selector switches
2 Function selector
switches ( push a
necessary function
switch with the select
switch passed.
3 Spindel rotation effective
key
4 Mode selection switches
5 Program START/FEED
HOLE swicthces
6 Axis move switches
NO NAME
USE
- These are use for selecting operation mode: MDI
PROGRAM EDITING , MEMORY AUTOMATIC
OPERATION and TAPE AUTOMATIC OPERATION .
- CANCEL Z..A machine lock condition is applied to the Z axis
only.It ais convient if used for a program test run.
- This function enable checking of program coordinate values
without moving the axis.
- DRY RUN..a manual jog feed rate become valid instead of a
feed rate specified by the program
- These push button swithes start and stop te spindal. This
necessary to speed in advance
-These push button used for selecting operation mode . FEED and
ZERO RETURN
- FEED. This mode manual continuous feed. A feed axis and its
direction are selected by the axis and feed rate by the FEED RATE
switches.
- RAPID.this mode enabes a rapit reverse axis and its direction are
srelected by the push button switches (6) and a rapit traverse rate
(override) by he rpt OVERRIDE push button switches (17)ZERO
RETURN . for axis to be returned is the zero point select wth the
push button switches for a feed rate.
- FEED HOLD. This push button switch a program progress.
An axis doing operated stops and a red lamp located above
light up.
- This push button switches move the x,y,z and a(optional)
axes respectly
USE
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7 Initial position check
- APC INITIAL POSITION this lamp indicates that each
machine section is located at its specified position, when
executing automatic, pallet change (APC) command.
- ATC INITIAL POSITION this lamp indicates that each
machine section is located at its specified position, when
executing an automatic, tool change (ATC) command.
During T cycle operates, this lamp lights up.

8 Status Display Lamp

- ALARM A red lamp lights up when an alarm occurred.
- PROGRAM STOP When M00 or M01 is executed during
operation in an automatic mode, a red lamp lights up. It is
list off by starting or continuing the program.

9 Automatic power shut off

switch - This make the automatic power shut-off function effective.
After machining cycle is completed, power is automatically
shut off by M30 when no pallet exists.

10 Call right off

- This switches off the lighting call light ( yellow lamp melody
horning )

11 Work setter
- Make the following functions effective, make use of a
reference touch tool.
- TOOL SETTER Measure a tool length and a tool
diameter and automatically sets their offset amounts in the
offset memory.
- REF. SURFACE, REF. coordinate. Hole .. measures the
coordinate system shift amounts of the reference surfaces
and hole against the machine coordinate system an sets
them in the coordinate system an sets them in the
coordinate system shift memory.
- COORD. ALIGN By measuring 3 points on the
orthogonal or jig located on the x-y plane. Differences in
rotation angle with the x and y axes are calculated and
stored, thus compensating X axis and Y axis program
coordinate values.

NO NAME USE

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12 Safety check
- Measure a machining tool length by the 1 st program start.
Measure the work piece at an actual machining position
with the reference touch tool mounted to the spindle by
the 2st program start. A work piece-tool interference check
is made by Z axis approach (G00) command, adding the
tool offset amounts used for these two information.
- TOOL LENGTH.. Measures and stores the length of the
tool used for an actual machining program.
- COLLATOIN.. Sets the Z axis to a machine lock state,
operates the machine with an actual machining program
and checks whether there is an interference between the
work piece and tool when Z axis approaches.

14 Override
- MEMORY Memorizes optimum override values (feed
rate, spindle speed) found in trial cutting, etc.. making
them corresponding to the tools used.
- AUTO the override values memorized are automatically
input to a program.

15 Feedrate override
switches - These push button switches apply an override (ranging
from 0 to 200%) to feed rate in automatic (cycle)
operation. During a canned cycle for tapping, the override
is ignored, resulting in 100%.

16 Spindle override
switches - These push button switches apply an override (ranging
from 50 to 150%) to a spindle speed command.

17 Rapid override switches

- These push button switches apply an override (ranging
from 0 to 100%) to a specified rapid traverse rate. When
the power is turned ON, the override value becomes less
than 25%. In the manual operation, the rapid traverse rate
becomes 0-25%
Note : the manual feed is not available in 0%.

NO NAME USE
20 Coolant switches
- These push button switches work various kinds of coolant

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 indicated on them respectively. Each kind of coolant can
be turned ON/OFF manually even during automatic
operation.

21 Feed rate switches

- These push button switches select a manual jog feed rate
between 0mm/min and 5000mm/min. ( in case of the A
axis, it becomes between 10 deg/min and 1400 deg/min.)

22 Restart of block
- The RESTART OG BLOCK becomes effective by pressing
this switch and the indication lamp lights up. This
becomes ineffective by repressing this switch and the
indication lamp goes out. When the RESET OF BLOCK is
not provided as option, this switch becomes ineffective
and the indication lamp puts out.
- Through designating a sequence No. that is not restart by
this functions, the machining can be restarted by this
functions, the machining can be restarted from the block.

24 Power
- ON turns on the main power to the NC unit.
- OFF turns off the main power.

33 Single block
- Program command are executed one block by one block.
However, canned cycles are executed one cycle by one
cycle.

37 Cutting monitor
- The screen of the cutting monitor can be monitored.

38 Cutting monitor
- Monitoring data is automatically set by the AUTOMATIC
SETTING teaching cutting data.
- Select switch
- INEFFECTIVE makes the cutting monitor function
ineffective.
- INEFFECTIVE makes the cutting monitor function
effective.

NO NAME USE
41 Magazine rotation

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 (ATC) - The ATC magazine rotates to index tools.
- Forward rotation : CW

45 DOOR INTERLOCK
- Effective : interlock of door open becomes effective.
- Ineffective : interlock of door open becomes ineffective.

Fungsi setiap button pada Main Operation Box (2)

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NO NAME USE
28 Memory
- WRITE.. shift this switch to WRITE when writing or
correcting memory information.

29 Speed meter
- Indicates a spindle speed.

30 Load meter
- Indicates a spindle load to a motors rated power in terms of
percentages.

26 Emergency stop
(main/sub - Stops the machine completely. All motor are stopped and the
operation panel) NC unit is reset.

27 Memory
- LOCK.. protects the information stored in the NC unit.

24 Power
- ON.. turn on the main power to the NC unit.
- OFF.. turn off the main power.

37 Cutting Monitor
- The screen of the cutting monitor can be monitored.

39 Block skip
- This makes the block 2-9 effective

SOALAN 3

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Terangkan bagaimana prosedur untuk on dan off Mesin CNC Milling satu persatu.

Prosedur ON mesin

1. Pastikan terdapatnya udara termampat (Air compressor)

2. ONkan Main Switch Breaker

5. Onkan Butang
Power
CNC machine

3. Onkan Transformer 6. Tunggu sehingga Proses CNC

Booting Selesai

4. Onkan suis utam

mesin CNC
7.
Laraskan butang
CWdirection

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 8. Tekan butang Standby 9. tekan butang Zero Return

10. Z axis zero return- Move Z axis (+) direction

X axis zero return- Move X axis (+) direction
Y axis zero return- Move Y axis (+) direction

Prosedur OFF mesin

1. Bersihkan mesin

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2. Pastikan mesin berhentu pada semua bahagian (putaran spindle, program, coolant, chip,
conveyor dan sebagainya)
3. pastikan juga paksi Z, X dan Y berada di kedudukan Home Return.

4. Tekan butang Emergency

5. Offkan butang Machine Power

6. Offkan suis utama mesin CNC

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 7. Offkan Transformer

8. Offkan Main Switch Breaker

SOALAN 4

Sila nyatakan jenis paksi dan terangkan pengertian warna bagi alarm yang bewarna
hijau, oren dan merah pada mesin milling.

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 Terdapat 3 jenis paksi di dalam mesin CNC milling ini iaitu:-

a) Paksi X
b) Paksi Y
c) Paksi Z

Ketiga-tiga paksi ini digunakan untuk pergerakan

a) Paksi X dan paksi Y terdapat pada kedudukan horizontal plane

b) Paksi X pula berada pada sepanjang table
c) Paksi Z pula merupakan paksi yang menggerakkan mata alat

Ketiga-tiga paksi ini bersudut tepat antara satu sama lain.

Pengertian bagi warna alarm

a) Hijau Ketika mesin mengeluarkan alarm bewarna ini, operasi yang dijalankan
oleh mesin adalah mengikut prosedurnya.

b) Oren Ketika mesin mengeluarkan alarm bewarna ini, operasi yang dilakukan
akan mendatangkan masalah pada mesin jika diteruskan.

c) Merah ketika mesin mengeluarkan alarm bewarna ini, operasi yang dijalankan
oleh mesin adalah salah dan tidak dapat dibaca oleh mesin. Tindakan untuk
membetulkannya perlu dilakukan segera untuk mengelakkan mesin ini rosak.

SOALAN 5

Senaraikan satu persatu langkahlangkah untuk warming up bagi mesin milling.

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Warming up mesin terbahagi kepada 2 iaitu:

a) Warming up semasa memulakan operasi harian

Warming up sebelum memulakan operasi harian (30 minit)

30% daripada putaran maksimum spindle (10 minit)

50% daripada putaran maksimum spindle (10 minit)

80% daripada putaran maksimum spindle (10 minit)

b) Warming up apabila mesin tidak beroperasi lebih dari seminggu atau lebih.

# 50 Spindle of 10000 min specification (oil air lubrication)

Warming up selepas spindle tidak digunakan melebihi seminggu
(masa minimum warming up : 4jam)

Dengan 2500 min untuk satu jam atau lebih

Dengan 5000 min untuk satu jam atau lebih

Dengan 7500 min untuk satu jam atau lebih

Dengan 10000 min untuk satu jam atau lebih

# 40 Spindle of 20000 min specification (oil air lubrication)

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Dengan 5000 min untuk satu jam atau lebih

Dengan 10000 min untuk satu jam atau lebih

Dengan 15000 min untuk satu jam atau lebih

Dengan 20000 min untuk satu jam atau lebih

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