Mechanical Engineering

Department; Thapar
University

Manufacturing Processes
UT002
Introduction to manufacturing processes

Introduction to computer numerical control (CNC)

machines

G and M code programming for simple turning

and milling operations

introduction of canned cycles

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Mechanical Engineering
Department; Thapar
University Manufacturing Process

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 Mechanical Engineering
Department; Thapar
University Manufacturing

All of the above products are produced by a combination of various processes called
MANUFACTURING
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 Mechanical Engineering
Department; Thapar
University Products & No. of Parts

Single material products Multi material (parts) products 12,000 parts

>15,000 parts >6 million parts

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Mechanical Engineering
Department; Thapar
University What is Manufacturing?

Manufacturing is derived from the Latin:

manus= hand, factus=made

Manufacturing in its broadest sense, is the

process of converting raw materials into
products.

Manufacturing is the use of machines,

tools and labour to produce goods for use on
a larger scale.

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Mechanical Engineering
Department; Thapar
University Manufacturing as a Technical Process

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 Mechanical Engineering
Department; Thapar
University Selecting Manufacturing Processes
Machining
Excess material removed from the starting piece so what
remains is the desired geometry
Examples: turning, drilling, and milling; also grinding
and non-traditional processes

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 Mechanical Engineering
Department; Thapar
University Selecting Manufacturing Processes
Casting
Starting material is heated sufficiently to transform it into a
liquid or highly plastic state
Examples: metal casting, plastic moulding

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 Mechanical Engineering
Department; Thapar
University Selecting Manufacturing Processes
Forming and shaping
Starting material is shaped by application of forces that
exceed the yield strength of the material
Examples: (a) Forging, (b) extrusion

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 Mechanical Engineering
Department; Thapar
University Selecting Manufacturing Processes
Joining
These operations join two or more components to create a
new entity
Examples: (a) welding, (b) brazing, soldering

(a) (b)

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Mechanical Engineering
Department; Thapar
University

Machining Processes

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 Mechanical Engineering
Department; Thapar
University Machining Processes
Machine Tool Use for Machining

Lathe Milling Machine

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Mechanical Engineering
Department; Thapar
University Machine Tool Use for Machining

Shaping Machine Drilling Machine

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Mechanical Engineering
Department; Thapar
University Lathe

Components of Lathe
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 Mechanical Engineering
Department; Thapar Various Operations That Can Be Performed in Lathe
University
External
Turning Facing
Turning tool moves axially, Turning tool moves radially,
along the side of the workpiece along the end of the workpiece
removing material to form removing a thin layer of
steps, tapers, chamfers, and material to provide a smooth flat
contours. surface

Straight turning Facing

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 Mechanical Engineering
Department; Thapar Various Operations That Can Be Performed in Lathe
University
External
Grooving Cut-off (parting)
Grooving tool moves radially, Similar to grooving, cut-off tool moves
into the side of the workpiece, radially, into the side of the workpiece,
cutting a groove equal in width continues until the centre or inner
to the cutting tool. diameter of the workpiece is reached.

Grooving Cut-off (Parting)

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 Mechanical Engineering
Department; Thapar Various Operations That Can Be Performed in Lathe
University
External

Thread cutting
Threading tool, typically with a
60 pointed nose, moves axially,
along the side of the workpiece,
cutting threads into the outer
surface.

Thread cutting

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 Mechanical Engineering
Department; Thapar Various Operations That Can Be Performed in Lathe
University
Drilling
A drill enters the workpiece
axially through the end,
Cuts a hole with a diameter
equal to that of the tool.
Internal
Reaming
A reamer enters the workpiece axially
through the end
Enlarges an existing hole to the
diameter of the tool.
Performed after drilling to obtain both
a more accurate diameter and a
smoother internal finish

Twist drill
Reaming tool

Feed direction
Feed direction

Drilling Reaming

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Mechanical Engineering
Department; Thapar Various Operations That Can Be Performed in Lathe
University
Boring
A boring tool enters the workpiece
axially,
Cuts along an internal surface to
form different features, such as steps,
tapers, chamfers, and contours.
Enlarge the existing hole.
Internal
Tapping
A tap enters the workpiece axially
through the end
Cuts internal threads into an existing
hole.
The existing hole is typically drilled
by the required tap drill size that will
accommodate the desired tap.

Boring tool

Tapping tool

Feed direction Feed direction

Boring Tapping

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 Mechanical Engineering
Department; Thapar
University

Feed ( f ) mm/rev or mm/stroke

Feed ( f ) mm/rev, may be defined as the
small relative movement per cycle (per
revolution or per stroke ) of the cutting tool
in a direction usually normal to the cutting
speed direction.

Feed ( f ) mm/rev is the distance cutting tool

advances along length of workpiece for every
revolution of the spindle.

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 Mechanical Engineering
Department; Thapar
University

Feed Rate ( fr ) mm/min

Feed Rate ( fr ) : The feed can be

converted to a linear travel rate (Feed Rate)
( fr ) in mm/min by the formula

fr = Nf(2)

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 Mechanical Engineering
Department; Thapar
University

DEPTH OF CUT ( d ) mm
It is defined as the depth of penetration of
the tool into the work piece during machining.
or
In other words, it is the perpendicular
distance measured from the machined surface
to the unmachined surface of the work piece.
or
The thickness of material removed by one
pass of the cutting tool is called Depth of Cut.
 Mechanical Engineering
Department; Thapar
University

DEPTH OF CUT ( d ) mm

d =
Do - Df (3)
2

d depth of cut mm
Do original dia of the part mm
Df final dia of the part mm
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 Mechanical Engineering
Department; Thapar
University

CUTTING SPEED ( v )

Cutting speed may be defined as the rate (or

speed) that the material moves past the
cutting edge of the tool.
Rough Cut
Finish Cut
Material m/min m/min

Cast iron 18 24
Bronze 27 30
Aluminum 61 93

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 Mechanical Engineering
Department; Thapar
University

CUTTING SPEED ( v ) mm/min

v = Do N (1)

v cutting speed mm/min

N rotational speed rev/min
Do original dia of the part mm

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 Mechanical Engineering
Department; Thapar
University

CUTTING SPEED ( v ) mm/min

Do N (1
v = )
1000

v cutting speed m/min

N rotational speed rev/min
Do original dia of the part mm
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Mechanical Engineering
Department; Thapar
University

Computer Numerical Control (CNC) Machine

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 Mechanical Engineering
Department; Thapar Computer Numerical Control (CNC)
University

The functions of machine tool are partly or fully taken over by a

dedicated computer (i.e computer controlled),
A micro or minicomputer is assigned with machine tool,
The movements of machine components is controlled by coded
instructions in the form of numbers or letters (i.e program),
The program may be prepared by programmer or obtained from
drafting software (i.e Autocad),
The programs can be modified and displayed at the machine, along
with a simulated view of the process,
Availability of small computer with large memory and program editing
capabilities popular the use of CNC systems widely.

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Mechanical Engineering
Department; Thapar
University
Computer Numerical Control (CNC) Machine

Lathe Milling machine

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 Mechanical Engineering
Department; Thapar
University CNC Lathe G Code

G-code is the most widely used as numerical control (NC)

programming language
action to perform such as:
Where to move the cutting tool
How fast to move the cutting tool
Which path the cutting tool will move
Within a machine tool, a cutting tool is moved according to the
instructions of G-code through a toolpath and cuts away
material to leave only the finished workpiece.

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 Mechanical Engineering
Department; Thapar
University CNC Lathe G Code
G00 Rapid transverse (or, Rapid movement)
G01 Linear motion with feed
G02 Tool movement in clock wise direction
G03 - Tool movement in anti clock wise direction
G04 Dwell time (or, waiting time)
G17 XY plane
G20 Inches mode
G21 Metric mode (in mm)
G28 Go to machine home position in incremental mode
G98 Feed in mm/min
G99 Feed in rev/min
U Incremental mode in X- axis
W Incremental mode in Z- axis
X Absolute mode in X- axis
Z - Absolute mode in Z- axis

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Mechanical Engineering
Department; Thapar
University CNC Lathe M Code

M-code is used for Machine function / Auxiliary

function
Such as:
Rotation of spindle
Tool change
Program on or off

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 Mechanical Engineering
Department; Thapar
University CNC Lathe M Code

M00 Programme stop

M02 Program end. halts program execution. To execute the program once
again, the system must reset.
M03 Spindle rotation clockwise
M04 Spindle rotation anti-clockwise
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M30 - Program Stop and Rewind. This command is used to stop the spindle, turns
the coolant off, terminates and reset the CNC program
M98 Sub program calling
M99 Sub program end

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 Mechanical Engineering
Department; Thapar
University Workpiece zero points or Program zero point

On CNC machines, tool traverses are controlled by coordinating systems.

Their accurate position within the machine tool is established by Zero Points.
The position the workpiece zero point can be freely chosen by the programmer
with in the workpiece
The workpiece zero point should be placed along the spindle axis (center
line), in line with the finished contour.

Chuck Workpiece Zero point

X (+)

(0,0) Z (+)

Length of Workpiece

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 Mechanical Engineering
Department; Thapar
University G00 Rapid transverse (or, Rapid movement)
Chuck Workpiece
Syntax: Dia of w/p
Tool

G00 X_ Z_ X (+)

X= Co-ordinate in X-axis (0,0) Z (+)

Z= Co-ordinate in Z-axis
Length of Workpiece

Tool
Example: 25
G21 G98
G28 U0 W0 / Go tool to home position 2
M06 T0101 / Call tool no. 1
(0,0)
M03 S2500 / Rotate tool at a speed of 2500 rpm
G00 X25 Z2 / The position of tool
Position of tool
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 Mechanical Engineering
Department; Thapar
University G01 Linear Motion with Feed
Syntax:
G01 X_ Z_ F_
Tool will come to the
X= Co-ordinate in X-axis position at a feed rate
Z= Co-ordinate in Z-axis
F= Feed in mm/min 25 Tool
Example:
2
G21 G98
G28 U0 W0 / Go tool to home position (0,0)
M06 T0101 / Call tool no. 1
M03 S2500 / Rotate tool at a speed of 2500 rpm 30 X (+)
G00 X25 Z2 / First position of tool
25 24
G01 X24 F60 Z (+)
G01 Z -10 F60 / Final position of tool

after removing material

20 10
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 Mechanical Engineering
Department; Thapar
University G02 Tool movement in clock wise direction
Example:
Syntax:
G21 G98
G02 X_ Z_ R_ F_ G28 U0 W0 / Go to tool home position

X= Co-ordinate in X-axis M06 T0101 / Call tool no. 1

M03 S2500 / Rotate tool at a speed of 2500 rpm
Z= Co-ordinate in Z-axis
G00 X16 Z0 / First position of tool
R= Radius of curve
G02 X18 Z -2 R4 F60 / Final position of tool
G28 U0 W0 /Makes the tool to go to home position
18
M05 /Spindle stop

X (+) M30 /Program reset

R2
Z (+)

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 Mechanical Engineering
Department; Thapar
University G03 Tool movement in anti-clock wise direction
Example:
Syntax:
G21 G98
G03 X_ Z_ R_ F_ G28 U0 W0 / Go to tool home position

X= Co-ordinate in X-axis M06 T0101 / Call tool no. 1

M03 S2500 / Rotate tool at a speed of 2500 rpm
Z= Co-ordinate in Z-axis
G00 X8 Z0 / First position of tool
R= Radius of curve
G03 X24 Z -8 R8 F60 / Final position of tool
G00 X 25
24 G28 U0 W0 /Makes the tool to go to home position

X (+) M05 /Spindle stop

R4 M30 /Program reset
Z (+)
8

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Mechanical Engineering
Department; Thapar
University
Practice
G21 G98 ------ Initial Settings
G28 U0 W0 ------ Going to home position
M06 T1 ------ Tool Change Position No. 01
M03 S1500 ------ Spindle clockwise with 1500 RPM
G00 X32 Z5 ------ Tool Moving to Tool Entry Point of X32 Z5 at Rapid Traverse
G01 X31 F80 ------ Giving First depth of cut of 1 mm at a feed rate of
80 mm / min
G01 Z-25 ------ Moving the tool towards Z-25 mm
G01 X32 ------ Retract the tool in X axis
G00 Z5 ------ Moving the tool to Z5 position
G01 X30 F8 ------ Giving Second depth of cut of 1 mm at a feed rate of
80 mm / min
G01 Z-25 ------ Moving the tool towards Z-25 mm
G01 X32 ------ Retract the tool in X axis
G00 Z5 ------ Moving the tool to Z5 position
G01 X29 F80 ------ Giving Third depth of cut of 1 mm at a feed rate of
80 mm / min
G01 Z-25 ------ Moving the tool towards Z-25 mm
G01 X32 ------ Retract the tool in X axis
G00 Z5 ------ Moving the tool to Z5 position
G01 X28 F80 ------ Giving Fourth depth of cut of 1 mm at a feed rate of
80 mm / min
G01 Z-25 ------ Moving the tool towards Z-25 mm
G01 X32 ------ Retract the tool in X axis
G00 Z5 ------ Moving the tool to Z5 position
G28 U0 W0 ------ Going to home position
M05 ------ Stop the spindle
M30 --------Program stop and rewind

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 Mechanical Engineering
Department; Thapar
University G71 Multiple Turning Cycle
Syntax: This cycle is used when major direction of cut along

G71 U_ R_ the Z axis

G71 P_ Q_ U_ W_ F_

U= depth of cut in Z axis (First one)

R= Tool retract G70 Finishing cycle

P= Start block of the profile Syntax:
Q= Finishing block of the profile
G70 P_ Q_ F_
U= Finishing allowance in X axis (Second one)

W= Finishing allowance in Z axis P= Start block of the profile

F= Feed rate Q= Finishing block of the profile

F= Feed rate

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Mechanical Engineering
Department; Thapar
University
Example

O0001
G21 G98
G28 U0 W0
M06 T0101
M03 S1500 /Spindle clockwise with 1500 RPM
G00 X32 Z5 /Tool Moving to Tool Entry Point of X32 Z5 at
Rapid Traverse
G71 U0.5 R1 /Calling G71 Cycle and defining Cycle Parameters
X G71 P1 Q2 U0.1 W0.1 F100 /Defining Cycle Parameters
Z N1 G01 X18 F100
G01 Z0
G01 X20 Z-4
G01 Z-16
G03 X24 Z-20 R4
G01 Z-30
N2 G01 X32 Z-38
G70 P1 Q2 F80 /Finishing cycle
G28 U0 W0
M05
M30

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 Mechanical Engineering
Department; Thapar
University G74 Multiple Drilling Cycle

G74 R_ This cycle is designed for deep hole drilling

G74 X_ Z_ Q_ F
R - Return Amount, mm 1. The drill enters the w/p into a
X - Always Zero, mm predetermined a amount
Z - Drilling Depth, mm
2. Then backing off another set amount
Q - Depth of Cut in Z axis (in Micron)
to remove the chips

F - Feed Rate, mm

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 Mechanical Engineering
Department; Thapar
University G74 Multiple Drilling Cycle
25
G74 R_ X (+)
G74 X_ Z_ Q_ F
Z (+)

Example:
Drill
G21 G98
G28 U0 W0
M06 T0202 / Call tool no. 2
12
M03 S1000 / Rotate tool at a speed of 2500 rpm 50
G00 X0 Z5 / Tool Moving to Tool Entry Point of X0 Z5 at Rapid Traverse
G74 R1 / Calling G74 Cycle and defining parameters
G74 X0 Z-12 Q500 F100 / make drill upto 12 mm with 500 m doc
G28 U0 W0
M05
M30

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 Mechanical Engineering
Department; Thapar
University G76 Multiple Threading Cycle

G76 P(m) (r) (a) Q_ R_ D= Major Diameter

P= Thread Height
G76 X_ Z_ P_ Q_ F_
Thread Height, P = 0.613 x Pitch of
the Thread
m= no of passes for finishing operation Core dia= D 2 (P)
r= tool relief angle
a= thread angle, degree Pitch
Q= minimum cutting depth (m in software)
(mm in machine) Thread
Height
R= finishing allowance (in mm)
X= core diameter (in mm) Thread
angle
Z=Thread length, mm
Q= depth of cut for first pass (m in software/ mm in m/c)
P=thread height (m in software/ mm in machine)
F= Pitch
 Mechanical Engineering
Department; Thapar
University Example
M321.5 mm G21 G98 ------ Initial Settings
G28 U0 W0 ------ Going to home position
M06 T0101 ------ Tool Change Position No. 01
M03 S1500 ------ Spindle clockwise with 1500

X RPM
G00 X32.5 Z5
Z
G76 P040060 Q50 R0.04 ------ Calling G76 cycle
G76 X30.162 Z-14 P919 Q100 F1 .5
G28 U0 W0
M05
M30
Thread Height, P = 0.613 x Pitch of the Thread
= 0.613 x 1.5
P = 0.919 mm =919 m

Core diameter = Major dia 2 (P)

= 32 2 (0.919)
= 32 1.818
= 30.162 mm

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 Mechanical Engineering
Department; Thapar
University G94 Facing Cycle
Syntax: This cycle is used for stock removal in
G94 X_ Z_ F_ parallel tool path
X= Diameter to which movement is being 1.Rapid to Z position

made 2.Feed to X position

Z= Co-ordinate in Z-axis 3.Feed to start Z position

4.Rapid to start X position
F= Feed
Example:

G21 G98 25 Tool

G28 U0 W0

M06 T0101
X (+)
M03 S2500
Z (+)
G00 X26 Z2

G94 X0 Z -0.5 F60 / Final position of tool

2
Z-1

Z-1.5

Z-2

G28 U0 W0
 Mechanical Engineering
Department; Thapar
University G90 Straight Turning Cycle
Syntax: This cycle is used for stock removal in parallel tool
G90 X_ Z_ F_ path.
1.Rapid to x position
X= Diameter to which movement is
2.Feed to Z position
being made
3.Feed to start X position
Z= Co-ordinate in Z-axis 4.Rapid to start Z position
F= Feed rate
25 Tool
Example:
G21 G98 X21 15
G28 U0 W0 X20 X (+)
M06 T0101 G90 X19 Z -17 F60
M03 S2500 X18
G00 X26 Z2 X17 Z (+)
G94 X0 Z -0.5 F60 X16
Z-1 X15
Z-1.5 G28 U0 W0 2 mm
Z-2 M05
15 15 facing
G00 X25 Z0 M30
G90 X24 Z -32 F60
X23
X22

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 Mechanical Engineering
Department; Thapar
University
Different Measurement System
Absolute System Incremental System
Absolute dimension system always refers Every measurement is considered from

to a fixed reference point in the drawing. previously dimensioned position.

Incremental dimensions are distance
This point has the function of a coordinate
between adjacent points.
zero point. Defined by U and W
Define by X and Z

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 Mechanical Engineering
Department; Thapar
University Practice
32
R6
20

12 M 121.5

X
Z
21 3 3 15

O0001 G70 P1 Q2 F100 /Finishing cycle

G21 G98 G28 U0 W0
G28 U0 W0 M06 T0303 /Calling threading tool
M06 T0101 M03 S500 / Spindle clockwise rotation
M03 S1500 /Spindle clockwise with 1500 RPM G00 X13 Z0
G00 X32 Z2 /Tool Moving to Tool Entry Point of X32 Z5 at G76 P040060 Q50 R0.4 / Call & execute threading
Rapid Traverse cycle
G76 X10.162 Z-15 Q100 P919 F1.5
G71 U0.5 R1 /Calling G71 Cycle and defining Cycle Parameters
G28 U0 W0 / Tool home position
G71 P1 Q2 U0.1 W0.1 F100 /Defining Cycle Parameters M05
N1 G01 X12 F100 M30
G01 Z0
G01 X12 Z-18
G01 X20 Z-21
G01 X20 Z-42
N2 G01 X 32 Z-42
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Mechanical Engineering
Department; Thapar
University
Degree of Freedom in Milling

End milling tool

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 Mechanical Engineering
Department; Thapar
University Various Operations That Can Be Performed in Milling

End Milling Chamfer Milling Face Milling

A end mill axials axial A chamfer end mill A face mill machines a
cuts across the makes a cut along an flat surface of the
workpiece edge of the workpiece in order to
Machine a feature, workpiece provide a smooth finish.
such as a profile, slot, Create an angled
pocket, or even a surface, known as a
complex surface chamfer.
contour

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 Mechanical Engineering
Department; Thapar
University Various Operations That Can Be Performed in Milling

Drilling

Boring Reaming

Tapping

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 Mechanical Engineering
Department; Thapar
University Workpiece zero points or Program zero point

Z (+) Tool

X (+)
Thickness

Z (+)

Workpiece Y(+)
X (+)

Y (+)

X (+)
(0,0)
Width

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 Mechanical Engineering
Department; Thapar
University CNC Milling G Code

G90 Absolute method

G91 Incremental method
G94 Feed, mm/min
G95 Feed, mm/rev
G54 to G59 Work coordinate system
G43 Height offset in downward direction
H1 to H6 Height offset for tool
X Absolute mode in X- axis
Y Absolute mode in Y- axis
Z - Absolute mode in Z- axis

54
Mechanical Engineering
Department; Thapar
University

G01
G00

G01 X_ Y_ Z_ F_
G00 X_ Y_ Z_

G03 X_ Y_ Z_ F_
G02 X_ Y_ Z_ F_

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 Mechanical Engineering
Department; Thapar
University

O0002
G21 G94
G91 G28 X0 Y0 Z0 /tool go to home position
M06 T0101 / Call tool no. 1
M03 S2500 / tool rotates at a speed of 2500 rpm
G00 G90 G54 X0 Y0 /
G00 G43 H1 Z10
G00 X20 Y10
G01 Z-2 F100
G01 X10 Y20
G01 Y80
G02 X20 Y90 R10
G01 X80
G03 X90 Y80 R10
G01 Y20
Thickness of workpiece: 12 mm, Depth of cut: 1 mm, G01 X80 Y10
Feed rate: 100 mm/min, Speed: 2500, Dia of end mill: 5 mm G01 X20
G00 Z5
G91 G28 X0 Y0 Z0
M05
M30

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