1.

0 Title
CNC Plasma

2.0 Objectives
 To study about the principle and knowledge in CNC machine.
 To experience practically handling the advance machine.
 To gain knowledge about the processes that include in the production of product
 To study the defect that present on the product and the way to overcome it.

3.0 Introduction
Computer Numerical Control or CNC Machining is a process that is involves of computer
control machine to control machine tools. This machine usually used in the manufacturing
sector that manufacture of plastics and metal products. The common machine tools that can be
link between the operations from CNC include mills, lathes, grinders and routers. The CNC
usage is increasing in extent because of the competitive demands in industry. There are some
types of CNC machines such as CNC Plasma Cutting Machine, CNC Laser Cutting Machine
and CNC Milling Machine. The CNC Plasma Cutting Machine used for cutting 2D shapes and
molds, the CNC Laser Cutting Machine similar as plasma cutters but it is using a laser and the
CNC Milling Machine used for drilling and turning metals. In this experiment, we used CNC
Plasma Cutting Machine as the main machine.
 The basic concept of theory for CNC machine is the information is uploaded into the
program and the machine will follow. With CNC, the design or object that need to be manufactured
gets a custom computer program that been written in international standard language called G-
code and stored by machine control unit, a microcomputer that attached to the machine. The
program can trace the lines and convert it into parameters and data, and the rest is depends on the
machine tools. The machine tools that received the data will move in physical movements in
coordinate positions that generated using computer. The machine tools usually moves in three or
more axis which is x-axis, y-axis and z-axis.

CNC machine is one of the advance machines that have many benefits compared to other
machine. The important in manufacturing sector is to reduce cost and manufacturing time. The
first benefit is CNC machine can minimize on manufacture costs and time. By using CNC machine,
the surface area of raw material will be use entirely and reduce waste. The product can be produce
in complicated design with high accuracy. The process of the CNC machine is really efficient as
it can cut down the steps but can produce multiple of parts in short amount of time. The safety of
the user for this machine is highly safety as the machine is automated. Some of the production
involves dangerous machine tools like steel and metal. So, the processes do not involve the
machine operator in production. With increase in the competitive environment and demands, the
demand of CNC usage has increased to a greater extent.
4.0 Apparatus

Figure 4.1 CNC Plasma Machine Figure 4.2 Operating Panel

Figure 4.3 Inverter Welder Figure 4.4 Chipper Hammer

5.0 Experimental Procedures

1. A product was designed in the software by using CATIA V5R20. The size for the design were
set at 100mm x 100mm.
2. The file then be converted into a Drawing eXchange Format (DXF).
3. The file be transfer into the lab computer to generate the Computer Numerical Control (CNC)
code.
4. All the code be saved into a pen drive and the pen drive then be slot into the CNC machine for
the code to be read before the machine start the operation.

5. After the CNC machine were set up, a steel plate with a specific size then be prepared under
the cutter/nozzle of the machine.
6. The CNC machine was run and the plate was cut according to the design that been read with
CNC codes.

7. The product then be formed with 3D geometry shape. Sink the product into water to cool down
the temperature.
8. Complete the product by finishing process. The weld flux be chipped by using the chipper.
9. The finish product then be compared with the actual design by measured the dimension and
accuracy of the product.

10. The result of the product was taken and analysed.

6.0 Results

Figure 1: Final Product

Area for final product is 23.2cm²

7.0 Discussions

The CNC plasma machine is advance machines that widely used in industry as the demands
from customer for some product is increase. We will discuss about disadvantages and defect on
product of CNC machine. With the CNC machine mostly automated, the CNC machine operator
only needs basic skills. The manual skill will be replaced by machine so this can affect the old
skills to be lost. The chances for employment also will be decreased, with the less workers needed
because the CNC machine will replaced the worker. The costs for the CNC machines are expensive
compare to manually operated machines. The defects that can be seen in the product are the cut
quality and the presence of slag. The cut quality is depends on the selection of material and
thickness, the amperage and many more. The way of setting of the machine can affect the product.
It can lead to shortened parts life and reduced cut quality. If the amperage is low, the cut will
become not smooth but if the amperage is too high, the nozzle life can suffer. To overcome the
problem, the setting of the height for the torch needs to be correct and need a delay time. This can
ensure the better contact of electric and correct flow of gas through the torch. Next, the cutting
speed must be considered to increase to cut quality. The next defect is the slag. Slag is like a large
bubbly accumulation of dross. The slag produces because cutting too fast or slow. The slag can be
removes but it will be difficult especially if the high speed dross. The slag can be prevents by find
the correct speed so it will produce clean surface that needs little finishing only.
8.0 Conclusion

The objective of the experiment was accomplished. The experiment run well according to the
procedure. From the experiment, the guidelines of the CNC machine were being followed and a
better comprehension in the modes of operational of the CNC machine have been increased. The
different kind of current CNC machine were used. For a better finishing and increases of the
effectiveness CNC program, different type of preparatory (G codes) and miscellaneous function
(M codes) were utilized in the CNC part programming. To be conclude, the objective or target
understudies for the Numerical Control (NC) Programming and Computer Numerical Control
(CNC) processing machine has been effectively accomplished. Also for this era of industry 4.0,
CNC machine should be required in every manufacturing industry because of the outstanding
contribution. It has flexibility to produce high demand of complicated products with high accuracy
in large quantities. Because of the accurate measuring program, error should not be required unless
the wrong measurement is being key in into the program by the operator. Computer Numerical
Control (CNC) machines are flexible and require less manpower for industry 4.0.

9.0 Recommendations

From the experiment or lab that have been done, there were some recommendations and
improvement that can make during the experiment or lab was conducted. Firstly, the machine
needs to undergo several maintenance or daily checkup before process the machines. This can
ensure the machines from error during the lab or experiment was conducted. Error that happen
during the lab or experiment can affect the product that wants to produce. Next, the drawing need
to be in precise dimensions so that that not will be produce error when transfer it into coding. If
the coding problem, CNC machines cannot read the G-code and will happen error during the lab.
This can make production delay or will take more time complete it.
10.0 References

1) webservices.searchco.nl/man/lab-manual-for-metal-cutting-cnc.pdf

2) https://apps.txrxlabs.org/classes/36/cnc-plasma-cutting/

3) www.arizonaspring.com/cnc-plasma-cutting.html

4) Lecture notes by Dr Juri Saedon , Faculty Of Mechanical Engineering UiTM Shah Alam