Department of Mechanical Engineering

IIT MADRAS

Course Name: Mech. Eng. Lab 1

Course Code: ME3481

Title of the Experiment: Machining Centre - Programming and Tool Presetting

INTRODUCTION:

NC Machine:

Numerical control of machine tools may be defined as a method of automation in which

various functions of machine tools are controlled by letters, numbers and symbols. Basically,
an NC machine runs on a program fed to it. The program consists of precise instructions about
the methodology of manufacture as well as the movements. For example, what tool is to be
used, at what speed, at what feed and to move from which point to which point in what path.
Since the program is the controlling point for product manufacture, the machine becomes
versatile and can be used for any part. All the functions of an NC machine tool are therefore
controlled electronically, hydraulically or pneumatically.

In NC machine tools one or more of the following functions may be automatic:

 Starting and stopping of machine tool spindle.

 Controlling the spindle speed.
 Positioning the tool tip at desired location and guiding it along desired paths by
automatic control of the motion of slides.
 Controlling the rate of movement of the tool tip (i.e. feed rate)
 Changing of tools in the spindle.

Computer Numeric Control or CNC involves the use of a computer to process the
program and manufacture a product. CNC is generally more sophisticated than a numeric
control machine. A CNC machine does not require intervention of the operator and is fully
automated and as such manufacturing of products is a lot more faster as compared to a NC
machine.

Advantages of CNC machine over conventional machine:

A CNC machine tool outperforms its conventional counterpart in several ways:

  Flexibility in design & production: A program can be changed in CNC machine more
easily than in a NC machine. Moreover a CNC machine can carry out several operations
on a single workpiece without having to remove the workpiece.
 Operator’s skill: The accuracy of components produced by CNC machine depends
upon accuracy and ability of the machine and not the skill of the individual operator.
 Lower inpection time: High position accuracy and repeatability are the inherent features
of CNC machine. So it reduces the inspection time considerably.
 Minimum space: Since a single CNC machine can carry out several machining
operations separate machines are not required and hence there is more free space.
 Productivity: In a CNC machine, the cutting is brought to the machining position much
faster and efficiently than can be done manually in conventional machines. SO the time
for removal of metal increases considerably for a specific cycle time, compared to any
conventional machine.
 Reduction of scrap: Because of inherent accuracy and repeatability of a CNC machine
scrap materials are drastically reduced compared with conventional machine which
reduces the production cost of the component.
 Fixed cycle time: Time required to produce a component in a CNC machine is fixed
and not dependent on operator’s skill and efficiency.
 Time reduction: In conventional machining, if a component requires 10 to 12 setups to
finish the operation, it may require only 2 to 3 setups when it goes through CNC
machining, which drastically reduces the machining time.

Advantages of CNC over NC machines:

 Part program storage memory is huge.

 Part program editing is easy.
 Part program downloading and uploading is comparatively simple.
 Tool path can be simulated.
 Tool offset data and tool life management are relatively simple.
 More macros and subroutines are available.
 Dynamic storage of data is possible.
 It can accommodate additional support software for diagnostics and maintenance, etc.

VERTICAL MACHINING CENTRE:

A vertical machining centre (VMC) is a machining centre with its spindle in a vertical
orientation. High-end VMCs are high precision machines often used for tight tolerance
milling, such as fine die and mould work. Low cost vertical machining centers are among the
most basic CNC machine tools.

MACHINE SPECIFICATIONS:

 Machine Description:
 AMS Drill tap Machining Centre-Vertical-DTC 300 is a general purpose compact
flexible, productive, robust & high precision machine equipped for working to cater
different kind of prismatic/circular components suitable for tool rotating and job
stationery process. The machine is equipped with an automatic tool changer and rotary
table (optional) to increase the production by cutting down the unproductive time.

 Machine Capacity:
This machine can be used for drilling, tapping, milling, boring etc.,
a) Worktable size : 350 X 600mm
b) Job loading height : 955mm for standard table
: 1100mm for APC pallet
c) Day light area : 175 to 475mm for standard machine
: 180-480mm for machine with APC

 Machine Bed:
Material: Structural steel/cast iron Gr-30 logically ribbed & double stress relieved to
relieve both casting & machining stresses.

 Guideways:
The X,Y and Z axes are provided with preloaded linear motion rails to ensure minimum
maintenance and long service.

 Feed slide - Z axis (Vertical):

a) Type of feed : A.C. servo drive with ballscrew and pre-loaded nut
b) Feed range: 1mm/min to 10,000mm/min
c) Feed override: 0 - 150%
d) Rapid traverse: 32,000mm/min. as std. and 40,000mm/min as optional
e) Rapid override: 0 - 100%
f) Position feedback: Standard Rotary encoder (absolute type)
g) Motor torque: 7Nm
h) Max. Working stroke: 350mm
i) Max. stroke (between dead stops): 400mm
j) Axial thrust continuous: 200Kg

 Cross slide - Y axis (Horizontal):

a) Type of feed: A.C. servo drive with ball screw and pre-loaded nut
b) Feed range: 1mm/min. to 10,000mm/min
c) Feed override: 0 - 150%
d) Rapid traverse: 32,000mm/min. as std. and 40,000mm/min. as optional
e) Rapid override: 0 - 100%
f) Position feedback: Standard rotary encoder (absolute type)
g) Motor torque: 11Nm
h) Max. Working stroke: 300mm
 i) Max. stroke (between dead stops): 350mm
j) Axial thrust continuous: 300K.

 Spindle drive:
a) No. of spindles: 1No.
Spindle bearing diameter: 50mm Std.
b) Spindle taper: ISO 30
Tool holder taper: BT 30
c) Spindle speed range:
Standard: 60 to 6000rpm
Optional 1 (Direct drive): 80 to 8000rpm
Optional 2 (Direct drive): 100 to 10000rpm
Constant power range: 5.5kW max at 15min. of continuous running
3.7kW for continuous running
d) Spindle speed override: 50 - 120%
e) Type of motor: A.C. motor with transistor (PWM) control
f) Velocity feedback: (Std.) Taco generator
g) Speed feedback: Rotary encoder

PART PROGRAMMING:
 Character: This is the smallest unit of the CNC program. It can be a digit, letter or a
symbol.
 Word: Combination of alpha-numerical characters, creating a single instruction to the
control system.
 Block: A block is a collection of instructions. Each block is composed of several words.
In the control system each block end with EOB (end of block) code.
 Program: A CNC program usually begins with a program number, followed by blocks
of instruction in a logical order. The program ends with a stop code. Documentation
and messages to operator may be placed within the program.
 G codes: The program address G identifies a preparatory command and is often called
G code. The objective of using G code is to preset or prepare the control system to a
desired condition or to a certain state of operation.
 Modal G codes: This G code remains active from the moment of its first appearance
in the program till it is cancelled. There is no need to repeat a modal command in every
block.
 Miscellaneous functions: M codes are used to execute functions relating to operation
of the machine like turning on the spindle and setting direction of rotation. Some M
codes are also used to control the execution of the program like calling one or more
subprograms.
 Canned cycle: One or two blocks of code can be execute repeatedly. This is used to
replace many program blocks. The length of the program can become quite large if a
number of roughing cuts are involved. The repetitive motions can be embedded in a
 canned cycle. The advantages of using canned cycles are shorter programming time,
shorter program length and quick changes at the machine.
 Work offset: An offset used to adjust the location of every tool loaded in the machine.
On the lathe, the work offset changes the position of the turret in both the X and Z-axes.
Work offset is a method that allows the CNC programmer to program a part away from
the CNC machine, without knowing its exact position on the machine table. A special
preparatory command for the active work offset is needed in the program and the
control system will do the rest.
 Geometry offset: Distance from machine zero to program zero of each work piece is
measured and input into the appropriate work offset register.
 Wear offset: The purpose of wear offset is to compensate for tool wear and to make
the adjustments to geometry offsets. The tool number for a lathe has four digits. The
first two digits select tool and geometry offset number. The second two digits are for
wear offset register number.

M-CODES:

G-CODES: