3.

0 Apparatus

1. CNC Milling Machine

 CNC milling machine used in the experiment (Deckel Maho DMC

635V)

2. NC Program

 Using NC programming by CATIA CAM

3. Machine Controller

 Run the machine by download NC programming to machine controller.

4. Cutting tool

5. Rough stock datum setting

6. Work holding devices

 Run work holding devices is gripping the rough stock while it being
machined
4.0 Industrial Apparatus

1. GX 1000 (40" x 21" x 21")

Figure : GX1000 (40” x 21” x 21”) CNC Miling Machine

Superior design characteristics ensure Bridgeport 40-taper spindle GX-Series

vertical machining centers deliver many years of accurate and reliable machining
performance. These VMCs include a stiff and thermally-stable spindle, a rigid C-frame
fixed column design, and fixed pre-tensioned double-nut ball screws on all axes. The
unique Bridgeport-designed linear guide and guide truck configuration provides added
stiffness, damping and surface contact area. Unit is configured with three guideways
and five guide trucks on both the X- and Y-axis; two guideways and six guide trucks
on the Z-axis.

Features:

 Fanuc 0iMD CNC with 10.4” color LCD, Digital Fanuc Motors,
Encoders and Drives
 All positioning Accuracy & Repeatability to ISO 230-2
 (2) Spare sets of M-Codes
 Handheld Manual Pulse Generator
 Rigid Tapping
 4th Axis Preparation (ready to accept optional Rotary Table & Drive)
 Ethernet, RJ45 and RS232 ready
 On-board PCMCIA Card Slot
 Artificial Intelligence Contour Control (AICC)
 Nano meter interpolation
 Macro B
 Manual Guide i Conversational Programming
 Fully Interlocked Machine Guarding
 Complete Coolant System
 Low voltage Work Light
 Coolant Through Spindle Preparation for either 300 or 1,000 PSI
 Spindle Air Purge (to keep coolant from contaminating the spindle
bearings)
 Chip Flush System
 Air Gun
 Tool Kit
 Coolant Tank (95 gallons capacity)
 CAT 40 Big Plus
 30 Station Automatic Tool Changer
 (30) Pull Studs, coolant through
 One Year Warranty on Machine (Parts & Labor)
 Two Years Warranty on complete Fanuc System (Parts & Labor)
 208-230AC, 3-phase, 60 Hz, 74 FLA
 2. Datron M10 PRO

Product Specifications:

 +/- 5 micron position accuracy

 41" x 35" X, Y travel
 Rapid rates up to 30 meters per minute
 Acceleration = 5 meters per sec2
 3 to 5 axes
 Liquid-chilled, 40,000 RPM spindle
 HSK-25E tool holders with
 <3 micron runout
 Vertical mounting capability
 79" x 83" footprint
 Solid granite table
 German engineered precision

Figure : Datron M10 PRO

Product Applications:

 Tight-tolerance applications requiring speed and precision

 Rapid / high-volume material removal
 Aerospace and electro-mechanical parts
 High speed, precision micro hole drilling
 Precision machining of larger parts
 5 axis machining requiring superior surface finish
3. VF-5/50TR

Figure : VF-5/50TR

5-Axis Vertical Machining Center, 50" x 26" x 25" (1270 x 660 x 635 mm),
with removable 8.27" (210 mm) 2-axis trunnion rotary table, 50-taper geared-head, 30
hp (22.4 kW) vector drive, 30+1 side-mount tool changer, 710 ipm (18 m/min) rapids,
automatic chip auger, programmable coolant nozzle, 750 MB program memory,
coordinate rotation & scaling, color remote jog handle, macros, high-speed machining,
15" color LCD monitor, USB port, memory lock keyswitch, rigid tapping and 95-gallon
(360 liter) flood coolant system.
4. Datron M8CUBE

Product Specifications:

 40" x 32" X, Y travel

 48,000 - 60,000 RPM spindle
 Up to 30-tool ATC (24 with HSK-
E25)
 Cast polymer-concrete bed
 Windows-based control software
 Tall, flat screen monitor
 Keyboard & hand-held controller
 Ethernet networking capability
 Remote monitoring capability
 Full enclosure with safety lock-out
 Chip disposal cart

Figure: Datron M8CUBE

Product Applications:

 Multiple-shift production
 Minimal runout for microdrilling
 Fast milling of pockets
 Complex 3D milling with small tools
 Batch (nested) machining
 Aluminum housings and enclosures
 Profile milling in sheet material
 Extrusions & profiles
 Engraving and dies
 Tight tolerance requirements
5. CNC milling machine

Figure : CNC milling machine / 3-axis / horizontal / traveling-column

RONIN is a horizontal travelling column milling machine able to accomplish a

wide range of machining requirements for die & mound making, aerospace applications
and general machining. These factors are decisive in order to achieve high speed
machining and acceleration, together with high accuracy in finishing and contouring.

The RONIN structure is entirely made of special cast iron and distinguishes
itself from other products by the symmetry of the guiding systems as to the moving axes
and the thermo symmetry on the cross - vertical plane.

The monolithic column with lowered trim and the rectangular ram with variable
section together with the 4 guide way system, both for the vertical axis and the ram,
ensure the highest optimization of the stiffness. The wide range of product
configurations combined with the numerous milling accessories and rotary tables made
by FPT, allow us to satisfy the specific market demands and the most particular
machining requirements.
4.0 Experimental Procedure

4.1 Standard Operating Procedure Of Cnc Milling

1. Keep all guards in place while operating the machine.

2. While operating the milling machine allow no one else to touch it.
3. Keep hands away from moving cutting tools.
4. Do not make measurements of the stock while the milling machine is powered.
5. Do not allow large quantities of chips to accumulate around the work piece or
machine table. After stopping the machine, use a brush or rag to remove all excess
chips from the mill bed and stock.
6. Use a rag or Kevlar gloves to handle sharp cutting tools.
7. Cutting tools must be securely fastened in the machine spindle with the proper
accessory. Never try to tighten cutting bits or tools by hand.
8. Do not power the machine to tighten or loosen cutting bits or tools.
9. Work pieces and stock must be rigidly fastened to the mill bed with clamps, a vise, or
special fixtures.
10. Use appropriate speeds and feeds for the type and size of cutter being used and the
material being machined.
11. Make sure the cutting tool is clear of the work piece before starting the machine.
4.2 Procedure

1. The NC programming was designed in CATIA software in which the shape of the
work piece was built and the parts to be removed were drawn on the work piece.
2. The finished NC program was then uploaded by transferring the data from the USB
drive into the Computer Aided Manufacturing (CAM).
3. The data shown on the machine’s display screen were checked before proceeding as
the data suits the design desired.
4. The suitable cutting tools for the process were selected in order to obtain the optimal
shape required.
5. The wooden block was placed below the cutting tool and secured tightly to avoid any
misshape. The datum was then set at 0 for X-axis, Y-axis and Z-axis respectively.
6. A point datum was set at the middle of the work piece by selecting two highest points
diagonally on the block which point the middle of the work piece.
7. The machining operation begun as the START button was pressed and the operation
was monitored throughout the process to ensure and to minimize errors from
occurring.
8. The surface of the work piece was cleaned occasionally in which the excessed
materials need to be removed from the surface in order to obtain the exact shape.
9. The machine was switched off after the process is finished and the work piece was
removed from the machine and the finishing operation was done on the block.
10. The data of the NC programming have been copied from the machine for the results
and all were important details of the process were taken and recorded.