ASSIGNMENT 3:CNC 1

1.0 Introduction
Milling is the process of machining using rotary cutters to remove material by advancing a
cutter into a work piece. This may be done varying direction on one or several axes, cutter head
speed, and pressure. Milling are usually used to machine the flat surfaces and it can also produce
for irregular surfaces. Milling can be used to drill, cut, gears and produce slots.

CNC milling, or computer numerical control milling, is a machining process which

employs computerized controls and rotating multi-point cutting tools to progressively remove
material from the workpiece and produce a custom-designed part or product. This process is
suitable for wide range materials such as metal, plastic, glass, wood and etc. CNC machining
services is including mechanical, chemical, electrical and thermal processes.

CNC milling is mechanical machining process that includes drilling, turning and various
process. CNC milling process starts with 2D or 3D creation of part design. Then it is exported to a
CNC-compatible file format and converted by CAM software into a CNC program which can
design the process and the movement of the tools across the workpiece.

For our assignment, our group choose “First Aid Kit” logo as our design. The sign is always
found on hospitals, nursing homes, clinics, dispensary, ambulances, etc. The Blue Cross was
introduced in the US but it is not as popular as the Red Cross, which is found worldwide. Doctors
use this sign so that they can be easily identified, especially during an emergency. History of the
first aid kit logo; it is not plus sign but the sign of the red cross that founded by Henry Dunant about
150 years ago.

2.0 Numerical Value

 Dimension;
- Thickness = 50mm
- Length = 100mm

 Shape;
- Square.
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3.0 Experimental procedure

1) Sketch the design using Mastercamx7

Figure 3.1 : Sketch of first aid kit

2) Start with facing process

Figure 3.2: Toolpaths for facing

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3) Next is pocket(I) process.

Figure 3.3: Toolpaths for pocket(I)

4) Then, pocket (II) process.

Figure 3.4: Toolpaths for pocket (II)

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5) Next, contour and drill process.

Figure 3.5: Toolpaths for drill process.

Figure 3.6: Toolpaths for contour process.

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6) All of the 4 process is combined together. The path for each process is shown below

Figure 3.6: 4 process of the milling.

7) Operation and toolpaths for each process.

Figure 3.7: Operation manager

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8) G-Code and M-code for first aid kit design. (NC file have submitted on putrablast)

Figure 3.8: G-code and M-code for first aid kit design.

4.0 Discussion
There are 4 process that involve in this design which is facing, pocket, contour, and drill. First,
facing process. Face milling is milling of surfaces that are perpendicular to the cutter axis. Face milling
produces flat surfaces and machines work to the required length. In face milling, the feed can be either
horizontal or vertical. In face milling, the teeth on the periphery of the cutter do all the cutting. It is
important to have the cutter securely mounted to see that all end play or sloppiness in the machine
spindle is eliminated. When setting up the depth of cut, the workpiece should be brought up to touch
the cutter. After that the graduated dial on the transverse feed is locked and used as a guide to
determining the depth of cut.

Next, pocket process. Pocket milling allows the machinist to use an end mill type cutting tool and
machine away large amounts of material in a “Roughing” cycle prior to finishing the part. This is
safe the time and maximizes the amount of the material removal in order to make a first aid kit
design. There are different styles of pocket toolpaths which is zig-zag (back forth), concentric or
offset in/out and highspeed cutting paths. In this assignment. The pocket toolpaths that being used
is zig-zag.

Then, contour process. Contour milling can produce curves, circles, and even cones, like those
shapes. Contour milling produces a continuous curve of various degrees. Contour milling requires
extensive knowledge of complex programs and machinery to produce ultra-precise tolerances and
angles. Incredibly intricate industrial components and even works of art can be milled from massive
blanks using contour milling.

Next, drill process. Drilling is commonly implemented for mass production. The drilling sometimes
mills and sometimes turns. The largest time sink for CNC drilling is with tool changes, so for speed,
variation of hole diameters should be minimized. The fastest machines for drilling varying hole sizes
have multiple spindles in turrets with drills of varying diameters already mounted for drilling. For low-
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volume jobs, manual or semi-automated drilling may be sufficient. For hole patterns that have a lot of
differences in size and high volume, a geared head is most appropriate.

G-code and M-code

A G code in CNC programming controls the movements of a machine, dictating how and
where a machine should move to fabricate a part. G-code deals with the geometry of the hardware,
for example, straight cutting developments, penetrating tasks and determining the units of
estimation. For machinist, the problem of using G codes is it has different machines and variations
on standard set of numbers. So, the system will tell one device an action may indicate something
on another piece of equipment. Function of the G codes is to give the machine direction on how
and where to move. Different letter will dictate how the machine will moves and the number set of
the parametersGenerally, program directions tell the machining equipment to begin doing something.
The device will continue doing that until it receives a directive to stop. Machinists have to know when
to input computer instructions to halt as well as to start. Example of the G codes;

 G0: Go as fast as possible to a specified coordinate.

 G1: Move in a straight line.
 G2: Create an arc in a clockwise direction.
 G3: Make a counter-clockwise arc.

M code in CNC programming controls miscellaneous machine functions, including starting and
stopping specific actions or programs. M-codes deals with the configuration of the machine tools Such
as on/off commands and bringing back the machine to the origin or the cutting point. For specific
processes for example the machine needs to flood the system with coolant and shut it off after the
temperature drops. Using M commands allows the machinist to tell the device to change tools, turn on
the spindle, send coolant to the system or open the doors. Dozens of M operations exist, and operators
learn how to program to execute desired actions fast. M codes depends on the machine. Example of the
M-codes;

 M00:Stop whatever program is currently operating — axes, coolant flooding or

spindle.
 M01: This command indicates an optional stop for the program.
 M02: End of the currently running program.
 M03: Begin to move the spindle clockwise.
 M04: Start moving the spindle counter-clockwise or in reverse.
 M05: Stop moving the spindle.
 M06: Load on a different tool. Typically, this command comes with the T value. For
example, you may see "T1 M06."
 M08: Start flooding the system with coolant.
 M09: Stop the coolant flow.
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5.0 Conclusion

In conclusion, milling is commonly used in engineering field machine flat surfaces, but can
also produce irregular surfaces. Milling process is used to drill, make a pocket, contour and facing metal
using a CNC machine. The milling process in fabrication has been understand by and practiced by the
student. The student gets to learn each process in details and can design and arrange the processes by
using Mastercam. This process is suitable for wide range materials such as metal, plastic, glass, wood
and etc. CNC machining services is including mechanical, chemical, electrical and thermal processes.

6.0 References

1. [Book]: Kalpakjian, S., Schmid, S.R. (2014). Manufacturing Processes for Engineering Materials.
Prentice Hall.

2. [Book]: Brown & Sharpe 2. "Cam & Tool Design: Surface Cutting Speeds Chart". Automatic Screw
Machine Handbook. Providence, R.I.: Brown & Sharpe Manufacturing Co.

3. [Website]: ThomasNet® - Product Sourcing and Supplier Discovery Platform - Find North American
Manufacturers, Suppliers and Industrial Companies. (n.d.). Retrieve from:
https://www.thomasnet.com/articles/custom-manufacturing-fabricating/understanding-cnc-milling/

4. [Article]: Insperger, T., & Stépán, G. (2000). Stability of the milling process. Periodica polytechnica
mechanical engineering, 44(1), 47-57. Retrieved from: https://pp.bme.hu/me/article/view/1428