CNC Milling Machine

IENG 3309L–Manufacturing Process Lab

Group Member:

1. Devani Herast Tantya

2. Firmina Wenni

3. Muhammad Akbar Ramadhan

4. Widyatna Maharani Putri

Submission Date: November 26th, 2019

Faculty of Engineering and Technology

Sampoerna University

Fall 2019 - 2020

IENG 3309L–Manufacturing Process Lab 1

Table of Content

Cover……………………………………………………………………………………….1

Table of Content…………………………………………………………………………...2

Introduction………………………………………………………………………………..3

Objective…………………………………………………………………………………...3

Experimental Method…………………………………………………………………….4

I. Tools……………………………………………………………………………..5

II. Materials………………………………………………………………………...6

III. Design and Dimension…………………………………………………………6

IV. Method…………………………………………………………………………7

Result and Discussion…………………………………………………………………….10

Conclusion…………………………………………………………………………………13

References…………………………………………………………………………………14

IENG 3309L–Manufacturing Process Lab 2

 A. Introduction
This report presents an experiment in using CNC Milling machine. Milling is the
process of cutting and drilling material. A very basic principle of CNC milling is a
machining process in which use computerized controls and rotating multi-point cutting tools
in order to remove material from the workpiece and produce a desired-designed part or
product [1]. Milling machine uses a rotating cylindrical tool called a milling cutter. A spindle
is used to hold the milling cutter that can vary in form and size. This process can be applied
in many types of materials such as glass, plastics, wood, and metal. By having CNC Milling
machine in a manufacturing industry, with all its speciality, many benefits can be gotten.
There are advanced CNC milling machines with all latest features such as touch screen
integrated software control, swing arm Automatic Tool Change (ATC) and effective chip
management among others [2]. These heavy duty machines can carry out accurate milling
operations without causing unnecessary wastage to enable businesses lower costs and
enhance customer satisfaction. The high quality production enhances the reputation and good
will of companies among their clientele as they can provide high precision components at
reasonable rates and on a consistent basis [2]. CNC milling machines help scale down the
production costs in the long run by preventing wastage and increasing production while
ensuring quality and precision [2].

B. Objectives
• To understand the occupational safety during laboratory work/practice

• To understand the operation of the CNC-Milling engine and simulation of the chisel
movement

• To be able to program a CNC-milling engine for a geometry component and execute

it.

• To understand the simulation of chisel movements with or without help plotter CNC
Milling machine.

• To train students on how to analyze the process of implementing production a

component uses CNC milling machine.

IENG 3309L–Manufacturing Process Lab 3

 C. Experimental Method
i. Machine

Figure 1. CNC Milling Machine

IENG 3309L–Manufacturing Process Lab 4

ii. Tool
1. 2. 3.

Figure 2. CNC Milling Tools (1)

4. 5.

Figure 3. CNC Milling Tools (2)

1. Dial Indicator
2. Dial Indicator
3. Face Mill & End Mill
4. Masteramp Software
5. Apron and Masker

IENG 3309L–Manufacturing Process Lab 5

iii. Materials
For this lab activity, aluminum used as the material.

Figure 4. Aluminum
iv. Design and Dimension

Figure 5. Design of the specimen.

IENG 3309L–Manufacturing Process Lab 6

 v. Methods
1. Measure the dimension of the workpiece and record the measurement.
2. Decide the aspect that needed to get the expected result, such as, cutting tool
types, spindle speed, depth of thread, major and minor diameter, etc.
• Cutting tool:
#1 = Face mill
#2 = End mill
3. Input the data of the program below into the Mastercam to do the simulation
before the running in the actual machine.
Dynamic Opti Rough Peel Mill
Tool type: Tool type:
a. Flate end mill 4flute a. Flate end mill 4 flute
b. Ø 11 mm b. Ø 8 mm
Offset: Offset:
a. #1, #2, #3 a. #1, #2, #3
b. …………….. b. ……………..
Speed: Speed:
a. Spindle 1200 rpm a. Spindle 1500 rpm
b. Feed rate 800 mm/rev b. Feed rate 800 mm/rev
c. Rapid 50% c. Rapid 50%
Cut: Cut:
a. Depth of cut 5 mm a. Depth Of cut 2 mm
b. Step Depth of cut 1 mm b. Step Depth of cut 1 mm
c. Linking parameter (Minimum vertical) c. Top off stock -10
Coolant M08 d. Cut style (Parallel style)
Coolant M08
Pocket (Irregular) Pocket (Round)
Tool type: Tool type:
a. Flate end mill 4flute c. Flate end mill 4flute
b. Ø 11 mm d. Ø 11 mm
Offset: Offset:
a. #1, #2, #3 c. #1, #2, #3
b. …………….. d. ……………..
Speed: Speed:
a. Spindle 1200 rpm d. Spindle 1200 rpm
b. Feed rate 500 mm/rev e. Feed rate 800 mm/rev
c. Rapid 50% f. Rapid 50%
Cut: Cut:
a. Depth Of cut 5 mm e. Depth Of cut 5 mm
b. Step Depth of cut 1 mm f. Step Depth of cut 1 mm
c. Top off stock -10 g. Top off stock -10
d. Cut style (Parallel style) h. Cut style (Parallel style)
Coolant M08 Coolant M08

IENG 3309L–Manufacturing Process Lab 7

 Figure 6. Inputting the program data into the software.

4. After inputting all the variables needed, the machine will automatically convert it
into codes for the CNC systems to be executed.

5. Then put the milling tool into the machine.

IENG 3309L–Manufacturing Process Lab 8

 Figure 7. Putting tool in the milling machine.

6. Before running the milling machine, check the tightness by the dial indicator
since it can detect the vibration. But the dial indicator close to the machine and
the specimen. Tightened it up to prevent the inaccurate.

Figure 8. Putting the dial indicator.

7. After the workpiece clamped tightly, close the machine’s door, let it do the work,
and wait until the process is done.
8. Take the workpiece out of the machine and clean the workspace.

As the lab experiment conducted with the Mastercam and the code are already
provided, the measurement part was skipped. After that, the experimenters are
required to write down all G-codes and M-codes that are used, plus their own
functions, coordinates, etc. The results will be recorded in a table provided
beforehand.

IENG 3309L–Manufacturing Process Lab 9

 D. Results and Discussion

After inputting all the data needed, the CAM software will convert the CAD design
into a CNC program [1]. The design of the result and the cutting path is shown in Figure 1.

Figure 9. Result design

Below are the codes that will be run by the machine in order to achieve the expected
workpiece result (Filename: “Group 1 G code Tuesday 12.11.2019.NC”):

O0000(GROUP 1 G CODE TUESDAY 12.11.2019)

(DATE=DD-MM-YY - 14-11-19 TIME=HH:MM - 10:51)

(MCX FILE - E:\CNC MILL IE\CAMP\CNC MILLING GROUP 1 12 NOVEMBER

2019.EMCAM)

IENG 3309L–Manufacturing Process Lab 10

(NC FILE - E:\CNC MILL IE\G CODE\GROUP 1 G CODE TUESDAY 12.11.2019.NC)

(MATERIAL - ALUMINUM MM - 2024)

( T1 | FLAT END MILL - 11 | H1 )

N100 G21

N110 G0 G17 G40 G49 G80 G90

N120 T1 M6

N130 G0 G90 G54 X36.809 Y64.281 S1200 M3

N140 G43 H1 Z50.

N150 Z41.8

N160 G1 Z34.8 F25.

N170 X36.881 Y64.216 F800.

N180 X36.953 Y64.166

…1

N3200 X36.042 Y63.635

N3210 X36.091 Y63.585

N3220 G0 Z30.2

N3230 Z50.

N3240 M5

N3250 G91 G28 Z0.

1
The middle part of the codes consists of cutting tool movement, respect to x, y, and z-axis. This
segment was trimmed as it was too long (1,291 lines) because it records each small change of tool
movement in all axis.

IENG 3309L–Manufacturing Process Lab 11

N3260 G28 X0. Y0.

N3270 M30

All codes hold their own meaning and functionality. The N-Codes are the
titles of a block of G-Code; N-Codes functions as the line number [3]. In this experiment, the
N-Codes began at N100 up until N9990 with the increment of 10. After it reached the
N9990, the N-Codes will start again at N100.

The codes begin with G21 which means the machine will be using metric
(millimeter in this experiment) programming selection, rather than using inch. G0 means
rapid motion, so the tool will move as fast as possible the machine could do; G17 indicates
that the machine will work on the XY plane; G40 means that there are no Cutter Diameter
Compensation (CDC), which restrict the machine to position its tool to the right or left [4];
the G49 works almost the same as G40, but this code is for canceling Tool Length
Compensation; G80 is the code that is responsible for the lengthy whole codes, because it
cancels out the canned cycle. Canned cycle allows the machine to perform complicated
action in a much shorter code without the needs to type all the details [4]; G90 means the
machine uses absolute programming, instead of the incremental one; G54 shows the work
offset.

The T1 code signs that it will use the Tool number 1, which is a flat end mill.
In the other hand, the M6 code will command the CNC milling machine to change its tool
automatically based on the user inputs, so the operator does not need to change it manually
anymore. S1200 signify the spindle speed which in this case, 1200 RPM. M3 code will
instruct the spindle to move forward, not reversed. G43 H1 Z50 codes mean that the Tool
Length Compensation will be using tool offset 1 with 50 mm length to the positive z-axis. G1
Z34.8 F25 signs that the tool will move linearly to coordinate Z 34.8, at a feed rate of 25. The
program will continue to use the 6 letters alternately: X (coordinate at x-axis), Y (coordinate
at y-axis), Z (coordinate at z-axis), S (spindle speed), F (feed rate), and T (tool number).

After the work is done, the machine will be instructed to stop the spindle with
code M5 and return to machine zero (X0, Y0, and Z0) by the command G28. Code G91

IENG 3309L–Manufacturing Process Lab 12

indicate that the return process will be done incrementally. Then lastly, the program will end
and reset by the code M30. The final workpiece result is shown in Figure 10.

Figure 10. Result of experiment

The experiment was done only until the programming part and the experimenters
were already provided on the actual result that has been made beforehand. The only error that
experimenters may face is by wrongly inputting the data, which results in wrong codes as
well. This error type might vary, from incorrectly inputting the measurement value, until
entering the wrong tool offsets. But these errors can still be avoided by doing simulation in
the program. If the program abruptly stopped and showing which process is error, means the
program still not ready yet to be executed. Otherwise, it is good to go.

E. Conclusion

The objective of the CNC Milling practicum is to understand occupational safety

during the practicum, to understand the process or how to operate the machine and its
simulations, to be able to program the CNC milling machine based on the geometry of its
components, to understand the simulation of chisel movement with or without the assisting
point of the CNC milling machine, and to train students how to analyze the process of

IENG 3309L–Manufacturing Process Lab 13

implementing component production using a CNC milling machine. In addition, this
practicum is also carried out to understand the basic principle of CNC milling machines
where this machine is able to produce objects with a high level of complexity while
maintaining high accuracy and precision as well. This is able to be done by CNC milling
machine because the machine is computer based so it is enough to input data into the
program on the computer, then the program will be transferred and will be run by the CNC
milling machine. This practicum is carried out by following the instructions that have been
given and by still paying attention to safety precaution which has also been explained
previously. The equipment that needs to be worn are appron and mask, complete with the
tools needed during the practicum such as Dial Indicator, Face Mill & End Mill, and
Masteramp Software. In this practicum, students only do a simulation where students are
asked to program the machine using G and M code with the aim to produce predetermined
specimens. The specimen is made from aluminum. The result of the practicum is a program
that is ready to be run by a machine. Then, the errors that occur during the practicum are
almost entirely due to errors in inputting the code.

In the end of the practicum, students have been able to fulfill the objectives in this
CNC milling machine practicum where students are able to know how to input data into the
program, students are able to know what should and shouldn't be done during the practicum,
students are able to know how to operate the machine based on simulations that have been
carried out.

F. References

[1] Sampoerna University, “Module Syllabus IENG3109L Job 06 CNC Milling (Job Sheet
#06)”

[2] Cammachine. “Big Benefits of Having a CNC Milling Machine.” Cam Machine, 24 Sept.
2014, https://cam-machine.co.uk/big-benefits-cnc-milling-machine/.

IENG 3309L–Manufacturing Process Lab 14

[3] M. Deans, "G-Code: The CNC Programming Language," Autodesk Inc., 2017.
Available: https://www.autodesk.com/products/fusion-360/blog/cnc-programming-
fundamentals-g-code/. Accessed 24 November 2019.

[4] CNC Cookbook, Inc., "N-Code to PWM," Available:

https://www.cnccookbook.com/cnc-dictionary-n-to-pwm/. Accessed 24 November 2019.

IENG 3309L–Manufacturing Process Lab 15