1. business and industrial
2. manufacturing

i
Manufacturing Process Laboratory Telkom University
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CONTENT
Process Manufacture Laboratory Assistants
iii
1st MODULE: INTRODUCTION TO MANUFACTURING PROCESS AND PRODUCT
DESIGN
1
2nd MODULE: PROCESS PLANNING
55
3rd MODULE: COMPUTER AIDED MANUFACTURING (MILLING)
81
4th MODULE: COMPUTER AIDED MANUFACTURING (TURNING)
142
5th MODULE: NUMERICAL CONTROL CODE
180
6th MODULE: MACHINING PROCESS - MILL
201
7th MODULE: MACHINING PROCESS - LATHE
234
8th MODULE: MACH3 CNC ROUTER ENGRAVER UNIT CONTROLLER
263
9th MODULE: ASSEMBLY, FINISHING AND MOLDING
274
REFERENCE
295
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Process Manufacture Laboratory Assistants

Muhammad Agung Agriza

Dian Fatimah Putri

Desi Ariska

Nabilatushalihah R.H

Diki Elfan Reksawana

Yussiwi Purwitasari

Rifky Iqbal Yuriandi

Intan Geovani

Fiky RiyanDarmawan Pratama

Firda Ramadhena

Fauzan Nurrahman

Mohamad Walid Anshar

Hilman Syahir

Rizki Anggriawan

Riskika Dea Pratama

Lukfi Hafizh

Dian Ayu Aprianti

Miftakhul Huda Erik Permadi

Yogi Purnama Putra

R. Irwan Dwi Cahyo

Siti Zahra Perdananingsih

Muhamad Zamzam Anshori

Putra Ramadhan

Fauzi Ramadhian

David Simangunsong
Manufacturing Process Laboratory Telkom University
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1st MODULE
INTRODUCTION TO MANUFACTURING PROCESS AND PRODUCT DESIGN
Objective
1. Students are able to understand about Manufacture,
2. Students are able to understand about Computer Aided Design,
3. Students are able to understand the usage of CAD in manufacturing processes,
4. Students are able to use Computer Aided Design Software.
Tools
1. Computer
2. SolidWorks 2013
Basic Theory
Introduction
The word “manufacture” is derived from two latin words, manus = hand, and factus = made;
the combination means made by hand. Technologically, manufacturing is the application of
physical and chemical processes to alter the geometry, properties, and/or appearance of a given
starting material to make parts or products; manufacturing also includes assembly of multiple
part to make products. The processes to accomplish manufacturing involve a combination of
machinery, tools, power, and manual labor, as depicted in Figure 1.1. Manufacturing is almost
always carried out as sequence of operations. Each operation brings the material closer to
desired final state.
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Starting
Material
Processed Part
Manufacturing
Process
Scrap ans
Waste
Figure 1. 1 Manufacturing Process
From the economical side, manufacture is transforming raw material into an item with
value added due to some process and or assembling. The example is transforming sand
into glass, wood into table, and many more.
Manufacturing
Process
Value
Added $$
$
Starting
Material
Material in
processing
$$$
Processed
part
Figure 1. 2 Manufacturing Process From the Economical Side
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Manufacturing Processes
Manufacturing processes can be divided into two basic types: processing operations and
assembly operations.
a. A processing operation transforms a work material from state of completion to a more
advanced state that is closer to the final desired product. It adds value by changing the
geometry, properties, or appearance of the starting material. In general, processing
operations are performed on discrete work parts, but some processing operations are also
applicable to assembled items.
b. An assembly operation joins two or more components in order to create a new entity, called
an assembly, subassembly, or some other term that refers to the joining process (e.g., a
welded assembly is called a weldment). A classification of manufacturing processes is
presented in Figure 1.3.
Figure 1. 3 Classification of Manufacturing Process
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Fundamental Idea
The fundamental idea of manufacturing or production is to create (or produce) something that
has a useful form. This form is most likely predetermined, calculated, with a certain physical
geometry. Usually this geometry has certain tolerances that it must meet in order to be
considered acceptable. A tolerance outlines the geometric accuracy that must be achieved in the
manufacturing process. The "tightness" of the tolerances or in other words the allowed variance
between the manufactured product and the ideal product is a function of the particular
application of the product.
1. Geometric Modeling in CAD / CAM Software
The most important aspect of the product is the geometric design (including sizes and
shapes). The design is so important due to specify the tools, machines, materials and
manufacturing processes to be used. The design of the product should be made in detail
and must consider various other aspects related. Designing products with the manual
method will lead to higher costs and will spend a long time. To overcome these problems,
the design should be created in a geometric model by using computer. Among the usages
of computer in manufacturing, Computer Aided Design and Computer Aided
Manufacturing (CAD/CAM) are by the far the best known as well the best applications to
create, modify, analyze, and optimize the product design then translate it to real object.
2. Computer Aided Design (CAD)
CAD may be defined as a design processing using sophisticated computer graphics
technique, backed by computer software packages, to aid in the analytical, development,
costing, and ergonomic problems associated with design work. The implementation of a
CAD process on a CAD/CAM system is shown in Figure 1.4. Once a conceptual design is
materialized, the geometric model can be started. The choice of a geometric model depends
on the type of analysis to be performed.
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Figure 1. 4 The CAD Process
[Source: Alavala,2008, p.4]
Computer-aided Design (CAD) is defined as any design activity that involves the effective
use of the computer to create, modify, analyze, or document an engineering design. CAD
is most commonly associated with the use of an interactive computer graphics system,
referred to as CAD system (Groover, 2007).
Benefit of CAD
Today's CAD technology can provide the engineer/designer the necessary help in the following
ways (Rao, 2006, p.6):
1. Computer aided design (CAD) is faster and more accurate than conventional
methods.
2. The various construction facilities available in CAD would make the job of
developing the model and associated drafting a very easy task.
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3. In contrast with the traditional drawing methods, under CAD it is possible to
manipulate various dimensions, attributes and distances of the drawing elements.
This quality makes CAD useful for design work.
4. Under CAD you will never have to repeat the design or drawing of any component.
Once a component has been made, it can be copied in all further works within
seconds, including any geometric transformation needed.
5. You can accurately calculate the various geometric properties including dimension
of various components interactively in CAD, without actually making their models
and profiles.
6. Modification of a model is very easy and would make the designer's task improving
a given product simple to take care of any future requirements.
7. Use of standard components (part libraries) makes for a very fast model development
work. Also a large number of components and sub-assemblies may be stored in part
libraries to be reproduced and used later.
8. Several professional CAD packages provide 3D visualization capabilities so that the
designer can see the products being designed from several different orientation. This
eliminates the need of making models of products for realization and explaining the
concepts to the team.
Geometric modelling involves the use of a CAD system to develop a mathematical description
of the geometry of an object. The mathematical description called geometric model, is contained
in computer memory. This permits the user of the CAD system to display an image of the model
on a graphics terminal and to perform certain operations on the model.
Type of Geometric Model
There are various types of geometric models used in CAD, there are:
a. Two-dimensional (2-D) models
In two dimensions the drawings are built up with basic element as lines, circle bows, curves
and text. Two dimensions CAD drawings are obtained through that the solid model is
projected on a plane in a coordinate system.
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b. Three-dimensional (3-D) models
In three dimensions one builds up models with curves, surfaces, or solid models, depending
on if you need wire frame, solid or surface model. By adapting an original one can obtain
a projected image of the model. Surface and solid modelling are important in engineering
industry. Surface modelling has been used for designing curves surfaces in shipping and
consuming products.
Software
A typical CAD system consists of CAD software program. The software are:

AutoCAD

Catia

Cadkey

Hobbyists

Solidwork

Etc.
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Labwork
1. Upper movable mold half part
- Create a new Solidworks part.
-
Select sketch to make sketch 2D.
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Make Rectangular sketch and add dimension like the figure below.
-
Go to Feature and select Extruded Boss
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Enter 2.5 cm for depth and click ok
-
Add sketch on the surface of the object.
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Create “Centerline” 1cm upwards.
-
Make a Center Rectangle on the top point of the centerline as shown in the picture
below.
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Create a centerline along the 9.5 cm upwards, and then make the centerline back
laterally to the boundary lines of the rectangle.
-
Make 3 Point Arc sketch and add dimension like the figure below.
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Remove the Rectangle using the sketch tool “Trim to closest”
-
Use the Sketch Fillet with RADIUS 2 cm, until there is a yellow line like the figure
below.
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Use the Sketch Fillet with RADIUS 15 cm, until there is a yellow line like the figure
below.
-
Use the Sketch Fillet with RADIUS 4 cm, until there is a yellow line like the figure
below.
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Go to Features and select Extrude Cut, enter 0.3 cm for depth and select Flip side to
cut.
-
Make Corner Rectangle with dimension like the figure below.
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Go to Features and select Extrude Cut, enter 0.25 cm for depth.
-
And this is the Upper movable mold half part
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2. Lower Fixed mold half part
- Create a new Solidworks part.
-
Select sketch to make sketch 2D.
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Make Rectangular sketch and add dimension like the figure below.
-
Go to features and select Extruded Boss
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Enter 2.5 cm for depth and click ok
-
Add sketch on the surface of the object.
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Create “Centerline” 1cm upwards.
-
Make Center Rectangle on the point above centerline as figure below.
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Make centerline along the 9.5 cm upwards, and then make the centerline back
laterally to the boundary lines of the rectangle.
-
Make “3 Point Arc sketch” and add dimension like the figure below.
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Remove Rectangle sketch using the tool “Trim to closest”
-
Use the Sketch Fillet with RADIUS 2 cm, until there is a yellow line like the figure
below.
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Use the Sketch Fillet with RADIUS 15 cm, until there is a yellow line like the figure
below.
-
Use the Sketch Fillet with RADIUS 4 cm, until there is a yellow line like the figure
below.
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Go to feature and select Extruded Cut, enter 0.4 cm for depth and click ok.
-
Select sketch and click onto the surface so that the color to blue, and then click
"Convert Entities".
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-
Create a centerline 8 cm and line like the figure below
-
Use the Offset Entities, click on the line and then navigate down to the yellow line at
a distance of 0.4 cm and then click ok.
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Select "Linear Sketch Pattern" select blue line with a distance of 3 cm.
-
Use “Trim To Closest” in order the sketch like the figure below.
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Make “Centerline” like the figure below.
-
Make “sketch 3 Point Arc” with a radius 15 and line, like the figure below.
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Select “Offset Entities” then give a distance of 1.2 cm.
-
Select “Offset Entities” then give a distance of 1.8 cm.
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Use “Trim To Closest” in order the sketch like the figure below.
-
Make “Centerline” like the figure below.
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Create line may occur under and then click "Offset Entities", with a length of 0.4 cm
towards the top.
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Create line sketch like the figure below.
-
Use “Trim to closest” in order the sketch like the figure below.
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Go to feature and select Extruded Cut, enter 0.4 cm for depth and click ok.
-
Make Corner Rectangle with dimension like the figure below.
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Go to Features and select Extrude Cut, enter 0.25 cm for depth.
-
And this is the Lower Fixed mold half part.
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3. Hinge part
- Create a new solidworks part and make sketch with dimension like the figure below.
-
Go to Features and select Extruded Boss. After that, enter 4.2 cm for depth and click
ok.
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Make sketch like this.
-
Go to feature and select Extruded Cut. After that, select through all and click ok.
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Make sketch like this.
-
Go to feature and select Extruded Cut. After that, select through all and click ok.
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And this is the Hinge 1 part.
4. Hinge 2
-
Create a new solidworks part and make sketch with dimension like the figure below.
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Go to Features and select Extruded Boss. After that, enter 4.2 cm for depth and click
ok.
-
Make sketch like this.
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Go to feature and select Extruded Cut. After that, select through all and click ok.
-
Make sketch like this.
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Go to feature and select Extruded Cut. After that, select through all and click ok.
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And this is the Hinge 2 part.
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5. Steel
- Create a new part and make circular sketch with dimension like the figure below.
-
Go to feature and select Extruded Boss. After that, enter 4.2 cm for depth and click ok.
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Make circular sketch like this.
-
Go to feature and select Extruded Boss. After that, enter 0.1 cm for depth and click ok.
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And this is the Steel part.
6. Assembly
-
Create a new Solidworks document and choose Assembly, and insert all of the parts
by clicking browse.
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Go to assembly and select mate. The first step is assembly hinge 1 part and Lower
Fixed mold half part. Click face like the figure below.
-
And then click this. After that click ok.
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Then click this face, until there is a blue like the figure below.
-
And click this face. After that click ok.
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Then click this face, until there is a blue like the figure below.
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And click this face. After that click ok.
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The second step is assembly hinge 2 part and Upper movable mold half part. Click
face on upper movable mold half part until there is a blue face like the figure below.
-
Then click this face, until there is a blue like the figure below. After that click ok.
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Then click this face, until there is a blue like the figure below.
-
Then click this face, until there is a blue like the figure below. After that click ok.
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Then click this face, until there is a blue like the figure below.
-
And click this face. After that click ok.
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The third step is assembly Steel part and Upper movable mold half part. Go to mate
-
and select advance mate, after that select Width.
Choose width selection, and select face on the steel part like a figure below.
-
After that, choose tab selection and select face on the Upper movable mold half part,
and click ok.
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The last steps is assembly between steel part and hinge.
Go to mate and click face like the figure shown.
-
Then click this.
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After that click this.
-
And click this. Click ok.
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After that click this.
-
And click this. Click ok.
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All of the parts already assembled and this is the Shoe sole mold Product.
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2nd MODULE
PROCESS PLANNING
Objective
1. Students are able to understand the concept of process planing
2. Students are able to make process planning of part
Tools
1. Computer
2. Microsoft Excel
Basic Theory
Process planning, in the manufacturing context, is the determination of processes and resources
needed for completing any of the manufacturing processes required for converting raw
materials into a final product to satisfy the design requirements and intent and respect the
geometric and technological constraints (ElMaraghy and Nassehi, 2013).
Process planning is also described to be the interface between product design and
manufacturing (Scallan, 2003), and the work often includes coordination of product design
intentions and constraints imposed by the workshop (Ham, 1988).
Process planning is called manufacturing planning, process planning, material processing,
process engineering, and machine routing. Process planning can be defined as an act of
preparing processing documentation for the manufacturing of a piece, part or an assembly.
Process planning is the critical bridge between design and manufacturing. Design information
can be translated into manufacturing language only through process planning.
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Figure 2. 1 Process Planning
The manufacturing process selected must be an economical balance of materials, manpower,
product design, tooling and manpower, product design, tooling and equipment, plant space, and
many factors influencing cost and practicality.
The process must be selected in such a way that the produced product will be acceptable to the
consumer functionally, economically, and appearance wise.
The process planner therefore plays a desirable role not only to define a process plan but to
contribute with manufacturing knowledge to a competitive product design (Bagge, 2009;
Groche, et al., 2012; Inman, et al., 2013). These are the interaction between the process planner
and collaboration parties while developing a process plan.
Figure 2. 2 The Role of The Process Planner
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Fundamental Rules
Fundamental rules for the selection and planning of a manufacturing:
1. The process must assure a product that meets all design requirements of quality, function,
and reliability requirements of quality.
2. Daily production requirement must be met.
3. Full capacity of the machine and its tooling should be utilized.
4. Idle operator and idle machine time must be reduced to minimum.
5. The process must provide the maximum utilization of the minimum amount of material.
6. The process should be flexible enough to accommodate reasonable changes in design.
7. The process should be designed to eliminate any unnecessary operations and combine as
many operations as are physically and economically practical.
8. Capital expenditure that must be amortized over short periods must be kept as low as
possible.
9. The process must be designed with the protection of both the operator and the workpiece
in mind.
10. The process should be developed so that the final product will be produced at a minimum
cost to the enterprise as a whole.
The Engineering Approach
-
Establish the process objectives
-
Collect all the facts about the problem
-
Plan alternative processes
-
Evaluate alternative processes
-
Develop a course of action
-
Follow up to assure action and check results
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Type of Process Plan
To bring some clarity in different focuses for process planning, there are four process planning
levels, these levels are placed in order from a very low level of detail to a very detailed level
(ElMaraghy and Nassehi, 2013). In addition, the focus and output from each level are
identified.
Table 2. 1 Process Planning Levels (ElMaraghy and Nassehi, 2013)
Process
planning
level
Main focus of
Level of
Planning output at
planning at this level
detail
this level
Manufacturing
Generic
planning
Selecting technology
and rapid process
technologies and
Very low processes, conceptual
planning
plans, and DFx
analysis results
Macro
planning
Routings, nonlinear
Multi-domain
Low
plans, alternate
resources
Detailed process plans
Detailed
Single domain, single
planning
process
Detailed
(sequence, tools,
resources, fixtures,
etc.)
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Depending on the production environment divide in two which are as follows:
1. A Rough Process Plan
Table 2. 2 Rough Process Plan
by: T.C. Chang
Route Sheet
Part No.
S1243
Part Name:
Mounting Bracket
1.
2.
3.
4.
workstation
Mtl Rm
Mill02
Drl01
Insp
Time(min)
5
4
1
2. A Detailed Process Plan
Table 2. 3 Detailed Process Plan
PROCESS PLAN
Part No. S0125-F
Part Name: Housing
Original: S.D. Smart Date: 1/1/89
Checked: C.S. Good Date: 2/1/89
Workstation
ACE Inc.
Material:
steel 4340Si
Changes:
Approved: T.C. Chang
Setup
Date:
Date: 2/14/89
No.
Operation
Description
10
Mill bottom surface1
MILL01
see attach#1
for illustration
Face mill
6 teeth/4" dia
3 setup
5 machining
20
Mill top surface
MILL01
see attach#1
Face mill
6 teeth/4" dia
2 setup
6 machining
30
Drill 4 holes
DRL02
set on surface1
twist drill
1/2" dia
2" long
2 setup
3 machining
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Time
(Min)
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Process Planning Approach
There are basically two approaches to process planning which are as follows:
1. Manual Process Planning
In industry, most process plan are still prepared manually. In order to prepare process plan,
a process planner has to have the following knowledge:

Ability to interpret an engineering drawing

Familiarity with manufacturing processes and practice

Familiarity with tooling and fixtures

Know what resources are available in the shop

Know how to use references books, such as machinability data handbooks

Ability to do computations on machining time and cost

Familiarity with the raw material

Know the relative costs of process, toolings, and raw material
2. Computer Aided Process Planning (CAPP)
Computer-aided process planning (CAPP) helps determine the processing steps required
during a planning process. CAPP programs develop a process plan or route sheet by
following either a variant or a generative approach. The variant approach uses a file of
standard process plans to retrieve the best plan in the file after reviewing the design. The
plan can then be revised manually if it is not totally appropriate. The generative approach
to CAPP starts with the product design specifications and can generate a detailed process
plan complete with machine settings. CAPP systems use design algorithms, a file of
machine characteristics, and decision logic to build the plans.
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Process Planning Step
1. Study the overall shape of the part.
Use this information to classify the part and determine the type of workstation needed. For
example, design wooden stool. The stool has one seat, four legs and four supports, resulting
in a total of nine parts. These parts will be used for illustrations in the following sections.
Figure 2. 3 Wooden Stool Design
2. Thoroughly study the drawing.
Try to identify every manufacturing features and notes.
3. If raw stock is not given, determine the best raw material shape to use.
Raw material are commonly used in the manufacturing process are alumunium, brass &
cooper, plastics, stainless steel, wood and titanium. Each material has a different properties,
for example: alumunium has a good formability, weldability, and corrosion resistance ;
cooper has characteristics higher strength and excellent electrical conductivity; Steel has
low carboon steel, poor machinability but good formabilty and weldability.
4. Identify datum surfaces.
Use information on datum surfaces to determine the setups. A datum point is any point of
known or assumed coordinates, which is used as a reference and from which calculations
or measurements may be taken. A datum point can be used as a construction when
modelling geometry. There are different types of datum points that can be used, especially
in modelling.
a. Absolut coordinates:
Absolute positioning is moving to a defined point. It is absolute because it is a particular
position from some point of reference known by the machine, like a home position. If
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you give an absolute position, the machine moves to that same point from wherever it
is every time. The G-code G90 is used to select this type of programming.
Example of how to define absolute coordinate system:
Figure 2. 4 Example of Absolute Coordinate Graph
Step 1) Identify the co-ordinates of the origin in 3 dimensions
Step 2) Assume the Datum is located at the origin
Step 3) Create a table of X, Y, and Z co-ordinates of each letter labeled point; assume
z=0 for all lettered positions
The Datum for X, Y, and Z is the origin (0, 0, 0). The format for expressing X, Y, & Z
is (x, y, z) so, for example “Point A” = (5, 4, 0) when the datum is located at the origin.
“Point B” = (10, 5, 0) relative to the datum “Point B” is NOT relative to “Point A”.
Table 2. 4 Absolute Coordinate System
Point Datum
0
X
0
Y
A
5
4
B
10
5
C
-4
5
D
-9
7
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-7
-3
F
-4
-6
G
7
-5
H
5
-2
63
a. Incremental coordinates:
Incremental coordinates are referenced from the previous point as though the previous
point has become a new origin. The reference point is essentially moving with every
new coordinate. The G-code G91 is used to select this type of programming.
Example of how to define incremental co-ordinate system:
Figure 2. 5 Example of Incremental Co-ordinate Graph
Step 1) Identify the co-ordinates of the origin in 3 dimensions
Step 2) Assume the Datum is located at the origin
Step 3) Create a table of X, Y, and Z co-ordinates of each letter labeled point;
assume z=0 for all lettered positions
The format for expressing X, Y, & Z is (x,y, z). In incremental systems, every
measurement refers to a previously dimensioned position (point-to-point).
Incremental dimensions are the distances between two adjacent points. The
opposite moving signed with (-).
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For example downside move and left move.

“Point A” = (2,3)

“Point B” = Define that “Point A” is (0,0) so from “Point A” to “Point B”
the moving of x is 3 to the right, and the moving of y is 1 to downside. So
the incremental co-ordinate is (3,-1)

“Point C” = Define that “Point B” is (0,0) so from “Point B” to “Point C”
the moving of x is 10 to the left, and the moving of y is 1 to upside. So the
incremental co-ordinate is (-10,1)

And so on for define the other point.
Table 2. 5 Incremental Co-ordinate System
Point Datum
0
X
0
Y
A
2
3
B
3
-1
C
-10
1
D
-2
2
E
0
-9
F
3
2
G
9
0
H
-3
-3
5. Select machines for each setup.
There are many operations in process machining, such as:
 Milling
Milling operations are operations in which the cutting tool rotates to bring cutting
edges to bear against the workpiece. Milling machines are the principal machine
tool used in milling.
 Turning
Turning operations are operations that rotate the workpiece as the primary method
of moving metal against the cutting tool. Lathes are the principal machine tool used
in turning.
 Drilling
Drilling operations are operations in which holes are produced or refined by
bringing a rotating cutter with cutting edges at the lower extremity into contact with
the workpiece. Drilling operations are done primarily in drill presses but sometimes
on lathes or mills.
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6. For each setup determine the rough sequence of operations necessary to create all the
features.
Table 2. 6 Operation
Operation
Explanation
Facing
Facing is an operation of machining the
Picture
ends of a workpiece to produce a flat surface
square with the axis
Pocketing
In pocketing, you have to remove material
from the interior of a closed geometry.
Profiling
Profiling can be used as a finishing
operation after a pocketing or facing
toolpath, or it can be used alone.
Slotting
This method is used for cutting in, shaving,
and has an angle, or doing surfaces that are
difficult to reach.This operation generates a
tool path along the centerline to the right or
to the left of one or more profiles.
Drilling
This operation enables to perform drills and
other canned drill cycles.
Finishing
This is the last step of process plan for
making a part. In this process, the part will
be done of finishing process.
Note: (*) means this operation will be discussed more complete in the fourth module.
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7. Select tools for each operation.
Try to use the same tool for several operations if it is possible. Keep in mind the trade off
on tool change time and estimated machining time. Some of tools that usualy used in
manufacturing process:
Table 2. 7 Cutting Tools
Tools
Explanation
Face Mill
This type of knife is usually used for facing
Picture
surfaces.
End Mill
This type of blade sizes vary from very small
sizes to large sizes. Cutter is usually used to
make grooves on a flat or wedge and the blade
types are generally mounted in an upright
position (vertical milling machine), but in certain
circumstances can also be installed in a
horizontal position and directly mounted on the
milling machine spindle.
Ball Nose Mill
This type of knife has a blunt and rounded end.
This knife is usually used for a smooth surface
finishing.
Drill
This type of knives/chisel are used to make a
hole.
The cutting tool materials must process a number of important properties to avoid excessive
wear, fracture failure and high temperatures in cutting.
8. Select or design fixtures for each setup.
9. Estimate the machining time
10. Prepare the final process plan document. Make a routing sheet.
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Selection of Proper Tooling
In selecting dies, jigs or fixtures for a given process, there are three essential processes, that
demand the attention of considerations of process engineer:
-
Quality of the product
-
Total volume to be produced
-
Required rate of production
Effect of Operational Speed
Effect of operational speed on performance and economy:
-
Cutting speed influences the rate of production and performance economy.
-
Assuming product quality can be achieved independently from the speed, there are two
different opinions:
(1) The greater machine speed, the greater its output and lower product unit cost.
(2) Speed should be held so that longer tool life is achieved.
-
With the change in tool life due to change in operational speed, the overall production
speed and production time will be effected due to re-sharpening and resetting the tool.
Cutting Tool Material
 Carbon Steels
It is the oldest of tool material. The carbon content is 0.6-1.5 % with small quantities
of silicon, chromium, manganese, and vandanium to refine grain size. This material has
low wear resistance and low hot hardness. The use of these materials now is very
limited.
 High- Speed Steel (HSS)
They are highly alloyed with vandanium, cobalt, molybdenum, tungsten, and
chromium added to increase hot hardness and wear resistance. Can be hardened to
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various depths by appropriate heat treating up to cold hardness in the range of HRC 6365. The cobalt component give the material a hot hardness value much greater that
carbon steels. The high toughness and good wear resistance make HSS suitable for all
type of cutting tools with complex shapes for relatively low to medium cutting speeds.
The most widely used tool material today for taps, drills, reamers, gear tools,end
cutters, slitting, broaches, etc.
Figure 2. 6 Thread tap made of High- Speed Steel
 Cemented Carbides
These are the most important tool materials today because of their high hot hardness
and wear resistance. The main disadvantage of cemented carbides in their low
toughness. These materials are produced by powder metallurgy methods, sintering
grains of tungsten carbide (WC) in a Cobalt (Co) matrix ( it provides toughness). There
may be other carbides in the mixture, such as titanium carbide (TiC) and/ or tantalum
carbide (TaC) in addition to WC.
Figure 2. 7 Microstructure of Cemented Carbide
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 Ceramics
Ceramic materials are composed primarily of fine- grained, high- purity alumunium
oxide (AL2O3), pressed and sintered with no binder. Two types are available:
 white, or cold-pressed ceramics, which consists of only Al2O3 cold pressed into
inserts and sintered at high temperature.
 black, or hot-pressed ceramics, commonly known as cermet (from ceramics and
metal).
This material consists of 70% Al2O3 and 30% TiC. Both materials have very high wear
resistance but low toughness, therefore they are suitable only for continuous operations
such as finishing turning of cast iron and steel at very high speeds. There is no
occurrence of built-up edge, and coolants are not required.
 Cubic Boron Nitride (CBN) and syntetic diamonds
Diamond is the hardest substance ever known of all materials. It is used as a coating
material in its polycrystalline form, or as a single-crystal diamond tool for special
applications, such as mirror finishing of non-ferrous materials. Next to diamond, CBN
is the hardest tool material. CBN is used mainly as coating material because it is very
brittle. In spite of diamond, CBN is suitable for cutting ferrous materials.
Machining Time Formula
Machining time is the total amount of time it take to finish processing a part. Machining time
is a function of part size, depth of cut, feed, and speed. It can be calculated by dividing the
tool-path length by the feed speed.
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For drilling:
𝑡𝑚 =
𝐿 + ∆𝐿
𝑉𝑓
Where
𝑡𝑚 = 𝑚𝑎𝑐ℎ𝑖𝑛𝑖𝑛𝑔 𝑡𝑖𝑚𝑒, 𝑚𝑖𝑛𝑢𝑡𝑒𝑠
𝐿 = ℎ𝑜𝑙𝑒 𝑑𝑒𝑝𝑡ℎ, 𝑖𝑛𝑐ℎ𝑒𝑠
∆𝐿 = 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 ℎ𝑒𝑖𝑔ℎ𝑡, 𝑖𝑛𝑐ℎ𝑒𝑠
𝑉𝑓 = 𝑓𝑒𝑒𝑑 𝑠𝑝𝑒𝑒𝑑, 𝑖𝑛𝑐ℎ𝑒𝑠 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒
For Milling:

Machine speed (N)
N =

k* V
 * D1
Cutting Time (CT)
𝐶𝑇 =
𝐿 + 𝐿𝐴 + 𝐿𝑂
𝐹𝑚
Where:
N : Machine speed in revolutions/minute (RPM)
k is a constant to “correct” speed (V) and part diameter (Di ) units
V is desired cutting speed, a Handbook Value
D1 is cutter diameter
V given in surface feet per minute (SFPM), D1 in inches: k = 12
V given in meters per second (MPS), D1 in mm: k = 60000
V given in meters per minute (MPM), D1 in mm: k = 1000
n: Number of Teeth on Cutter
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W: Width of cut (may be full cutter or partial cutter)
t: depth of cutter engagement
V: cutting speed -- a Handbook value
L: Length of pass or cut
fm: Table (machine) Feed
ft: feed/tooth of cutter -- a Handbook value
D: Cutter Diameter
LA: Approach Length
LO: Length of “Over Travel”
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Lab Work
1. Study the overall shape of the part.
In this practicum, we make a process plan of a “shoe sole mold” that has been made in the
first module (part design). This product consists of five parts, including upper movable
mold, lower fixed mold, 2 hinges, and steel. The process plan that will be made by using
the lower fixed mold part.
Figure 2. 8 Part Design
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2. Thoroughly study the drawing.
3. Determine the best raw material shape to use.
Figure 2. 9 Stock
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As we know that there are several raw material are commonly used in the manufacturing
process such alumunium, brass & cooper, plastics, stainless steel, wood and titanium. In
this practicum, we choose wood as the material to produce the product.
The advantages of using wood, include: the low energy content needed for production, low
cost of production, wood is an environmentally friendly material, wood has low density,
etc.
4. Identify datum surfaces.
P2
P3
(0,0)
P1
P4
Figure 2. 10 Datum Surface
Table 2. 8 Datum Coordinate
Absolute Coordinate
Incremental Coordinate
X
Y
X
Y
P1
0
0
0
0
P2
0
150
0
150
P3
300
150
300
0
P4
300
0
0
-150
P1
0
0
-300
0
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5. Select machines for each setup.
In this practicum we do milling operation as process machining because the part has a flat
surface. Milling machine is able to work on a flat surface and grooved with the completion
and accuracy, is also useful for smoothing or leveling the workpiece in accordance with
the desired dimensions. Milling machines can produce a smooth flat surface.
6. For each setup determine the rough sequence of operations necessary to create all the
features.
Operation
Explanation
Picture
Facing
Facing is the first step in making a frame. In
this process, materials will be flattened. It
is because the surface of wood materials
were uneven and jagged.
Pocketing
This is a process of forming part of the
frame. Formation of the frame adapted to a
predetermined size.
Profiling
Profiling can be used as a finishing
operation after a pocketing or facing
toolpath, or it can be used alone.
Finishing
This is the last step of
frame making
process. In this process, the main frame will
be finished manually.
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7. Select tools for each operation.
Operation
Explanation
Facing
Tool that will be used in the facing process
Picture
is "End Mill". The function of this tool is to
flatten the surface of the workpiece.
Pocketing
In Pocketing, use the tool “ End Mill”. This
tools is usually used to make grooves on a
flat or wedge and the blade types are
generally mounted in an upright position
(vertical milling machine)
Profiling
Tool that will be used in the profiling
process is "End Mill". The function of this
tool is used to make grooves on a flat or
wedge and the blade types are generally
mounted in an upright position (vertical
milling machine)
Finishing
In the finishing process requires sand paper.
It is the process of smoothing the surface.
In this Lab work, we are using the tool High Speed Steel (HSS). Because HSS has lower
cost than the carbide. And it is commonly used in each process operation. The advantage
of HSS over carbide is its strength to withstand cutting forces and the low cost of the tools.
From the tool life point of view, HSS performs very well at intermittent cutting
applications.
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8. Select or design fixtures for each setup.
9. Estimate the machining time
Terms used:
N : Machine speed in revolutions/minute (RPM)
k is a constant to “correct” speed (V) and part diameter (Di ) units
V is desired cutting speed, a Handbook Value
D1 is cutter diameter
V given in surface feet per minute (SFPM), D1 in inches: k = 12
V given in meters per second (MPS), D1 in mm: k = 60000
V given in meters per minute (MPM), D1 in mm: k = 1000
n: Number of Teeth on Cutter
W: Width of cut (may be full cutter or partial cutter)
t: depth of cutter engagement
V: cutting speed -- a Handbook value
L: Length of pass or cut
fm: Table (machine) Feed
ft: feed/tooth of cutter -- a Handbook value
D: Cutter Diameter
LA: Approach Length
LO: Length of “Over Travel”


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 Facing Operation
Where:
V: 18,84 mm/min
D1: 6 mm
L : 150 mm
o Spindel Speed (N)
N=
𝑁=
k*V
 * D1
1 𝑥 18,84
3,14 𝑥 0,006
𝑁 = 1000 𝑅𝑃𝑀
o Cuting time (CT)
𝐿 + 𝐿𝐴 + 𝐿𝑂
𝐹𝑚
𝐷
𝐿𝐴 = 𝐿𝑂 =
2
6
𝐿𝐴 = 𝐿𝑂 = = 3
2
𝐿 + 𝐿𝐴 + 𝐿𝑂
𝐶𝑇 =
𝐹𝑚
𝐶𝑇 =
𝐹𝑚 = 𝐹𝑡 𝑥 𝑁 𝑥 𝑛
𝐹𝑚 = 0.05 𝑥 1000 𝑥 2 = 100 𝑚𝑚/ 𝑚𝑖𝑛𝑢𝑡𝑒𝑠
𝐶𝑇 =
150 + 3 + 3
100
𝐶𝑇 = 1,55 = 93 𝑚𝑖𝑛𝑢𝑡𝑒𝑠
 Pocketing Operation
Where:
V: 18,84 mm/min
D1: 6 mm
L : 166 mm
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o Cutting Speed (N)
𝑁 = 1000 𝑅𝑃𝑀
o Cutting Time (CT)
𝐶𝑇 =
𝐶𝑇 =
𝐿 + 𝐿𝐴 + 𝐿𝑂
𝐹𝑚
166 + 3 + 3
= 1,72 = 103.2 𝑚𝑖𝑛𝑢𝑡𝑒𝑠
100
 Profiling Operation
Where:
V: 18,84 mm/min
D1: 6 mm
L : 42 mm
o Cutting Speed (N)
𝑁 = 1000 𝑅𝑃𝑀
o Cutting Time (CT)
𝐿 + 𝐿𝐴 + 𝐿𝑂
𝐹𝑚
(42 ∗ 2) + 3 + 3
𝐶𝑇 =
= 0,26 = 15,6 𝑚𝑖𝑛𝑢𝑡𝑒𝑠
100
𝐶𝑇 =
 FINISHING
It takes 5 minutes to finishing the frame by using the sanding tool.
10. Prepare the final process plan document. Make a routing sheet.
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ROUTING SHEET
Part No. 1
Material : Wood
Part Name : Main part of Shoe
Changes : ______ Date : ______
Sole Mold
Approved : .......... Date : 14/1/2015
Original : Prosman Lab
Date : 31/12/2014
Checked : Prosfams
Date : 14/1/2015
No
Operation
Workstation
Setup
Tool
Material
Description
1
Facing top
Pocketing
Result
(Min)
MILL01
surface
2
Time
MILL02
Setup
End
Tool
Mill
external
60 mm
-
End
the surface
HSS
93
minutes
HSS
mill
103,2
minutes
60 mm
3
Profiling
PROF01
-
End
HSS
mill
15,6
minutes
60 mm
3
Finishing
FIN01
-
Sanding sandpaper
tools
5
minutes
By summing all the available processing time, the total time required to perform the machining
process part is 216,8 minutes or about 3 hours 37 minutes.
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3rd MODULE
COMPUTER AIDED MANUFACTURING (MILLING)
Objective
1. Students are able to understand about machining process.
2. Students are able to understand about classification of CNC machine.
3. Students are able to create machining process using 2,5 axis and 3 axis CNC operations.
4. Students are able to simulate machining process using CAM software.
Tools
1. Computer
2. SolidCAM 2013
3. Part
Basic Theory
Introduction
Machining is a term used to describe a variety of material removal processes in which a cutting
tool removes unwanted material from a workpiece to produce the desired shape. The workpiece
is typically cut from a larger piece of stock, which is available in a variety of standard shapes,
such as flat sheets, round tubes, rectangular bar and etc.
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Classification
Machining process can be divided into three basic types: conventional machining, abrasive
process, and non-traditional machining.
a. Conventional machining process is a machining process with a particular geometry. The
three primary processes are turning, drilling, and milling.
 Turning
Turning is a machining process to produce cylindrical parts of machine which is done
with lathe machine.
 Drilling
Drilling is a cutting process in which a hole is originated or enlarged by means of a
multipoint, fluted, end cutting tool.
 Milling
Milling is a process of slicing the workpiece using a cutting tool with a rotating
multiple cutting point.
b. Abrasive process is the removal of materials using abrasive materials, such as grinding
processs. Grinding is the most popular form of abrasive machining. It involves an abrasive
tools consisting of grain of hard materials which are forced to rub against the workpiece
removing a very small amount of material.
c. Non traditional machining process is carried out chemically and electrically with the help
of optical power sources.
 Mechanical energy process
Mechanical energy is used for removing material from workpiece. In this process,
cutting tool with sharp edge is not used but material is removed by the abrasive action
of high velocity of stream of hard, tiny abrasive particles. The particles are kept
vibrating with very high velocity and ultra high frequency to remove the material.
 Electrochemical machining
In this category of non-traditional machining electrical energy is used in the form of
electrochemical energy or electro-heat energy to erode the material or to melt and
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vaporized it respectively. Electrochemical machining, electroplating or electro
discharge machining are the examples work on this principle.
 Thermal energy process
According to this principle heat is generated by electrical energy. The generated
thermal energy is focused to a very small portion of workpiece. This heat is utilizedin
melting and evaporating of metal. The example based on this principle is electric
discharge machining.
 Chemical machining
According to this principle of working chemicals are used to erode material from the
workpiece. Selection of a chemical depends upon the workpiece material. Example
of this type of machining is electrochemical machining. The same principle can also
be applied in reversed way in the process of electrochemical plating.
A classification of machining process is presented below :
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CNC Machine
CNC (Computer Numerical Control) is a machine that controlled by a computer using a
numerical language (movement command using character and digit) in its process. So, with a
CNC machine we don’t need to control a turning, drilling, milling, and other conventional
machining process manually, but we can use a computer. CNC can be analogous to a printer
machine. When we want to make an article, we must make it first in computer then print it with
a printer machine. It is similar when we want to make a product, we must make a design in
computer then cast it with a CNC machine. CNC machine can be divided in two basic types,
these are:
a. CNC Machine Two Axis (Lathe Machine)
CNC Lathe Machine can be divided in two basic types, these are:
1. CNC Lathe Machine Training Unit (CNC TU)
2. CNC Lathe Machine Production Unit (CNC PU)
Both of these machines have the same working principle, but they have a different function.
CNC TU is used for basic training of CNC programming and process that is equipped with
EPS (External Programing System). It can only be used for light work with a soft material.
Figure 3.1 Lathe Machine
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CNC PU is used for a mass production. This machine is equipped with additional
accessories such as automatic opening system that applies hydraulic principle, exhaust
chips, and so on.
The movement of this machine is controlled by a computer, so all the movements in
accordance with a program. The advantages of this system is the machine enable to repeat
the same movement constantly with the same level of carefulness.
CNC lathe machines have the basic principle of the movement as well as conventional
lathes, that is the movement to transverse direction and horizontal to the X and Z axes
coordinate system. The working principle between two of them are same that the workpiece
is mounted in moved dibble then the cutting tool is not moving.
These are the symbols of lathe machine’s movement direction:
 X axis for transverse and perpendicular movement to rotary axis
 Z axis for lengthwise and in parallel to rotary axis
The function of lathe machine’s axis can be seen below:
Figure 3.2 Function of lathe machine’s axis
b. CNC Machine Three Axis (Milling Machine)
CNC Milling Machine can be divided in two basic types, these are:
1. CNC Milling Machine Training Unit (CNC TU)
2. CNC Milling Machine Production Unit (CNC PU)
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Both of these machines have the same working principle, but they have a different function.
CNC TU is used for basic training of CNC programming and process that is equipped with
EPS (External Programing System). It can only be used for light work with a soft material.
Figure 3.3 Milling Machine
CNC PU is used for a mass production. This machine is equipped with additional
accessories such as automatic opening system that applies hydraulic principle, exhaust
chips, and so on. The working principle of this machine is the work table moves transverse
and horizontal then the cutting tool rotates.
These are the symbols of milling machine’s movement direction:
 X axis for horizontal direction movements
 Y axis for transverse direction movements
 Z axis for vertical direction movements
Shaping
Shaping is a process of slicing or cutting a static workpiece (the workpiece is clamped) then the
cutting tool moves straight forward and backward. Shaping process can be divided into three
basic types:
a. Facing. Facing is used to create a flat surface.
b. Pocketing. Pocketing is used to remove material in closed geometry.
c. Profiling. Profiling is used to remove material in open geometry.
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Drilling
Drilling is a process of producing round holes in a solid material or enlarging existing holes
with the use of multi-point cutting tools called drills or drill bits. Here are the classification of
drilling processes:
a. Reaming.
Reaming is a process of enlarging the hole with a very high accuracy dimension.
Figure 3.4 Reaming
b. Tapping
Tapping is a process of making an inside screw.
Figure 3.5 Tapping
c. Counter boring
Counter boring is a process of enlarging the existing hole.
Figure 3.6 Counter Boring
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d. Counter sinking
Counter sinking is similar with counter boring, but the point of cutting tool is conical.
Figure 3.7 Counter Sinking
e. Center drilling
Center drilling is a process of making a short space which is not translucent. The cutting
tool has a single point with a straight groove. The cutting point is on the side of the cutting
tool which has a tapered shape.
Figure 3.8 Center Drilling
f. Spot facing
Spot facing is a process of creating a flat surface around the hole to accommodate the bolt
head or mur.
Figure 3.9 Spot Facing
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Definition of CAM
Computer-aided manufacturing (CAM) is an application technology that uses computer
software and machinery to facilitate and automate manufacturing processes. The example of
CAM software are Solid CAM or Rhino CAM. In CAM software there are usually a simulation
menu and options, where you can simulate the process you made in a program before machining
it for real. The output from CAM software is NC Code, this code will be input for CNC machine
for further processing into the machine.
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Advantages of CAM
The advantages of using CAM are (Rao, 2006, p.9):
1. Greater design freedom: Any changes that are required in design can be incorporated at
any design stage without worrying about any delays, since there would Hardly be any in
an integrated CAM environment.
2. Increase productivity: In view of the fact that the total manufacturing activity is completely
organized through the computer, it would be possible to increase the productivity of the
plant.
3. Greater operating flexibility: CAM enhances the flexibility in manufacturing methods and
changing of product lines.
4. Shorter lead time: Lead times in manufacturing would be greatly reduced.
5. Improved reliability: In view of the better manufacturing methods and controls at the
manufacturing stage, the products thus manufactures as well as of the manufacturing
system would be highly reliable.
6. Reduced maintenance: Since most of the components of a CAM system would include
integrated diagnostics and monitoring facilities, they would require less maintenance
compared to the conventional manufacturing methods.
7. Reduced scrap and rework: Because of the CNC machines used in production, and the part
programs being made by the stored geometry from the design stage, the scrap level would
be reduced to the minimum possible and almost no rework would be necessary.
8. Better management control: As discussed above, since all the information and controlling
functionsare attempt with the help of the computer, a better management control on the
manufacturing activity is possible.
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SolidCAM 2.5D
SolidCAM offers you the following types of 2.5D Milling operations:
Face
Profile
Contour 3D
Pocket
Drilling
Thread Milling
Slot
T-Slot
Translated Surface
ToolBox Cycles
a. Face Milling Operation
This operation is enables to create smooth surface in flat stock.This process using end mill
as the tool.
Figure 3.10 Face Milling Operation
b. Profile Operation
This operation enables to remove material in open geometry
Figure 3.11 Profile Operation
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c. Pocket Operation
This operation enables to remove material in closed geometry
Figure 3.12 Pocket Operation
d. Slotting Operation
This method is used for cutting in, shaving, and has an angle, or doing surfaces that are
difficult to reach. It can also be used for processs that require vertical cuts.
Figure 3.13 Slot Operation
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e. T-Slot Operation
This operation enables to machine slots in vertical walls with a slot
mill tool.
Figure 3.14 T-Slot Operation
f. Drill Recognition
This Operation carries out a highlyefficient drill recognition and geometry creation with
the functionality of the AFRM- module (Automatic Feature Recognition and Machining).
In this operation drilling on different levels can be carried out. The drilling levels are
automatically recognized but may be edited by the user.
Figure 3.15 Drill Recognition
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g. Pocket Recognition
This Operation recognizes automatically pocket features at the target model and creates the
necessary machining.
Figure 3.16 Pocket Recognition
h. Thread Milling
Operation this operation enables you to generate a helical tool path for the machining of
internal and external threads with thread mills.
Figure 3.17 Thread Milling
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SolidCAM 3D
Solid CAM provides you with powerful 3D Machining functionality that can be used both for
prismatic parts and for complex 3D Models. For complex shape models such as molds,
electrodes and prototypes, SolidCAM offers powerful 3D Machining, including integrated
options for material machining. This operation offers a wide range of roughing, semi-finishing
and finishing strategies for free-form models.
a. 3D Milling Operation
Using this operation, you can calculate the tool path for the rough, semi-finish and finish
machining of the 3D Model. A number of strategies can be applied to provide you with
effective and high-quality machining.
Figure 3.18 3D Milling Operation
b. 3D Engraving Operation
This operation enables you to perform the engraving of text or artwork on the part
faces.
Figure 3.19 3D Engraving Operation
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c. 3D Drill Operation
This operation enables you to perform drills that take into account the 3D Model Geometry.
Figure 3.20 3D Drilling Operation
Labwork
Labwork Procedure 2.5 D Operation
A. Setting Process
1. Open the part in SolidWorks software.
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2. Go to SolidCAM Part.
3. On the SolidCAM Part menu, select New →Milling.
4. SolidCAM is started, and the New Milling Part dialog box is shown below.
New Milling Part dialog box SolidCAM enables you to create a new CAM-Part using one
of the following options:
 External mode in this mode, the part you create is saved in SolidCAM format (*.prt,
*.prz).
 Internal mode in this mode, the part you create is saved inside SolidWorks part
(*.sldprt, *.sldasm).
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5. The SolidCAM interface can be seen below.
6. Choose the machine that will be used.
7. Define Coordsys Option. Click the Define button in the Coordinate System area to define
the Machine Coordinate System. After click define button, click the upper surface of the
part.
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8. After determines the coordinates, CoordSys Data appears to show the coordinates of the
machines that used in the machining process. This dialog box enables to define the
machining levels such as Tool Start Level, Clearance Level, Part Upper Level, etc.
There will be box like below, just click OK.
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9. Select Stock from the Stock & Target model tab.
10. Add 5 mm on Z+ to be used in facing process then select Add box to CAD model →OK.
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11. Select Target at Stock & Target model.
12. Click the part until the color of the part changes into purple and then select OK.
B. Machining Process
 Facing Operation
1. Go to SolidCAM Operations.
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2. To make a facing operation, in SolidCAM Operations select 2.5D →Face.
3.
Go to Geometry page. Then select the geometry to choose a surface that will be faced.
Click New button, the position is beside of facemill text.
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4.
Choose target in Base Geometry box, then click OK.
5.
The yellow line shows the surface of the stock that will be used in facing operation.
6.
Go to tool page.
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7.
Click Add Milling Tool to select the tool.
8.
Choose FaceMill.
9.
Define the Tool Parameters.
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10. Go to Levels page then define the positioning levels and milling levels.
11. Switch to the technology page, then choose Hatch for the movement of the tools.
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12. Click Save and Calculate button.
13. Do simulation of the facing operation.
14. Choose Solid Verify, then click play button.
15. After that click this icon to Exit
→
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 Profiling Operation
1. After facing operation is complete, then the next step is Profiling. To make a profiling
operation, in SolidCAM Operations select 2.5D → Profile.
2.
Select icon New in Geometry page to define the geometry.
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3.
Choose side surface of the part that will be profiled, then click √ symbol in Chain List
box and click OK.
4.
Go to Tool page. The step to choose the tool is same like the previous operation. In
profiling operation the tool is end mill.
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5.
Go to Levels page. Click and define the upper level and profile depth as shown below.
For upper level click the upper surface of part (see the blue color).
For profile depth, click the surface in area that shown in blue color.
6.
Go to Technology page then define the technological parameters. First, click the
geometry button.
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If the position of red circle isn’t like the picture below, just change in Tool Side box.
7.
Then fill the technology page like below.
8.
Click offset button in technology page. For step over, just write 2.
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Then click the line like below. Choose the line that shown in blue line.
9.
Click Save and Calculate button, then simulate.
10. Do simulation of the profiling operation.
11. Repeat the steps of profiling process for other side.
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 Pocketing Operation
1.
The next step is pocketing operation. To make a pocketing operation, in SolidCAM
Operations select 2.5D → Pocket.
2.
Go to Geometry page then define the geometry. Click all the under edges like shown
below.
3.
Go to tool page then select the tool tht will be used for pocketing operation. In
pocketing process, the tool is end mill.
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4.
Go to Levels page then define the upper level and profile depth.
 For upper level
 For profile depth
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5.
Switch to Technology page and select Contour from Technology tab.
6.
Click Save and Calculate and do simulation for the pocketing operations.
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7.
Repeat the pocketing steps for other side.
Use multi-chain on the Geometry page, and select the chosen surface. It will
automatically detect the existing line on the part.
1.
In SolidCAM Operations select 2.5D → Pocket.
2.
Go to Geometry page then define the geometry. Choose Multi-chain box and click add
button. Then click the surface like below.
3.
The interface will be like this.
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4.
Then choose end mill as the tool.
5.
Fill the technology page like below.
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6.
Click Save and Calculate button then do simulation.
 Slotting Operation
1.
After the pocketing operations done, the next step is slotting operation. To make a
slotting operation, in SolidCAM Operations select 2.5D → Slot.
2.
Define the slot geometry.
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3.
Go to Tool page then define the tool that will be used. Choose end mill.
4.
Go to Levels page, the upper level is the highest level of parts that will be slotted.
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5.
Go to Technology page then define the Depth from Slot Levels tab.
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6.
Click Save and Calculate button then do simulation for slotting operation.
 Drilling Operation
1.
The last process is Drilling. To make a drilling operation, in SolidCAM Operations
select 2.5D →Drill.
2.
Go to Geometry page then define it as shown below.
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3.
Go to Tool page then define the tool that will be used.
4.
Go to Levels page then define it as shown below.
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5.
Go to Technology page then define it as shown below.
6.
Click Save and Calculate button then do simulation for the drilling operation.
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 T-Slot Operation
1.
To make a T-slot operation, in SolidCAM Operations select 2.5D → TSlot.
2.
Define the geometry.
3.
Define the upper level and T-slot depth
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4.
Click Geometry button in Technology page. If the position of red circle isn’t like this,
change in tool side box.
5.
Fill the technology page like below.
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For offset value, click the offset button, then choose the line like shown in blue color.
6.
Go to Link Page.
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7.
Click Save and Calculate button then do simulation.
8.
These are all of the machining process for the part above.
Labwork Procedure 3D Operation
A. Setting Process
1. Open the part in SolidWorks software.
2. Go to SolidCAM Part.
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3. On the SolidCAM Part menu, select New →Milling.
4. SolidCAM is started, and the New Milling Part dialog box is shown below.
New Milling Part dialog box SolidCAM enables you to create a new CAM-Part using
one of the following options:
 External mode in this mode, the part you create is saved in SolidCAM format (*.prt,
*.prz).
 Internal mode in this mode, the part you create is saved inside SolidWorks part
(*.sldprt, *.sldasm).
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5. The SolidCAM interface can be seen below.
6. Choose the machine that will be used.
7. Define Coordsys Option. Click the Define button in the Coordinate System area to
define the Machine Coordinate System. After click define button, click the upper
surface of the part.
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8. After determines the coordinates, CoordSys Data appears to show the coordinates of
the machines that used in the machining process. This dialog box enables to define the
machining levels such as Tool Start Level, Clearance Level, Part Upper Level, etc.
There will be box like below, just click OK.
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9. Select Stock from the Stock & Target model tab.
10. Select Target at Stock & Target model.
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11. Click the part until the color of the part changes into purple and then select OK.
B. Machining Process
1. Choose 3D Milling Operation.
2. Define the geometry.
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3.
Define the tool.
4.
Define the upper level and lower level in Level Page.
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5.
Define the Technology Page.
6.
Click Save and Calculate button then do simulation.
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7.
The next step is choose engraving operation.
8.
Define the geometry using multi-chain step. Click add in multi-chain box
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9.
Define the tool. Choose engraving as the tool.
10. Define the upper level and engraving depth.
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11. Define the technology.
12. Click Save and Calculate then do simulation.
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13. The last step is 3D Drilling Operation. Click 3D Dilling button.
14. Define the geometry.
15. Define the tool.
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16. Define the upper level
17. Define the lower level.
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18. Define the value of offset from model.
19. Define the technology.
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20. Then save and calculate. Click the Simulate button to simulate.
21. These are all of the machining process for the part above.
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4th MODULE
COMPUTER AIDED MANUFACTURING (TURNING)
Objective
1. Students are able to understand concept of turning process.
2. Students are able to understand the CNC Turning components and each function.
3. Students are able to create and simulate machining process by using SolidCAM 2013.
Tools
1. Computer
2. SolidCAM 2013
Basic Theory
Introduction
Turning is a form of machining, a material removal process, which is used to create rotational
parts by cutting away unwanted material. The turning process requires a turning machine or
lathe, workpiece, fixture, and cutting tool. The workpiece is a piece of pre-shaped material that
is secured to the fixture, which itself is attached to the turning machine, and allowed to rotate
at high speeds. The cutter is typically a single-point cutting tool that is also secured in the
machine, although some operations make use of multi-point tools. The cutting tool feeds into
the rotating workpiece and cuts away material in the form of small chips to create the desired
shape.
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Figure 4. 1 Turning Process
Turning is used to produce rotational, typically axi-symmetric, parts that have many features,
such as holes, grooves, threads, tapers, various diameter steps, and even contoured surfaces.
Parts that are fabricated completely through turning often include components that are used in
limited quantities, perhaps for prototypes, such as custom designed shafts and fasteners.
Turning is also commonly used as a secondary process to add or refine features on parts that
were manufactured using a different process. Due to the high tolerances and surface finishes
that turning can offer, it is ideal for adding precision rotational features to a part whose basic
shape has already been formed.
Component of CNC Turning
Figure 4. 2 Component of CNC Turning Center
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Table 4. 1 Description of CNC Turning
No
1
Component
Sheet metal
Description
Protective housing that contain cutting chips and capture
coolant for recycling.
2
Door
The door is closed during operation.
Lathes can be dangerous if the part is thrown or a tool
breaks during machining.
The window is made from a special high impact glass.
The lathe should not be operated if this glass is cracked.
3
Spindle
The spindle is attached at one end the machine drive
system. The other end attaches the chuck, which grips
the part.
4
Turret
The turret holds and moves the tools. Tools are bolted
to the turret using a variety of specialized holders,
depending on the type of tool. The turret indexes to
present the tool to the work piece.
5
Control
The CNC control used to operate the machine.
The spindle turns the chuck. The chuck grips the part using hard jaws, soft jaws, or collet. The
most common configuration is the three jaw chuck. The chuck requires air pressure to open and
close the jaws, and set the gripping force. Pressure must be high enough to securely hold the
part, but not so great as to deform fragile parts.
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Figure 4. 3 Turret
Turret, tool holders bolt to either the front or perimeter of the turret. Tool changes are made by
the machine indexing the turret to place the appropriate tool closest to the part.
The method by which the tools are attached to the turret, and the direction the tool faces in
relation to the part, vary depending on the tool, operation, and cut direction. For example, a
facing tool is oriented radially to the part, to maximize tool rigidity and work envelope. A boring
bar is oriented axially to allow the bar to enter and exit the bore.
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Table 4. 2 Description of Tool
No
1
Component
Tool Station
Description
The turret is divided into stations evenly spaced around the perimeter.
Most lathes with tool turrets have about 10 tool stations. Tools are
connected to the turret by a tool holder and tool block. The tool holder
and block used depend on the type of tool and mount direction.
2
Tool Block
Tool blocks act as the interface between the tool holder and the turret.
They bolt to the face or perimeter of the turret. Different blocks are used
depending on the type of tool and orientation.
3
Turn Tool
Turning tools, which includes face, OD rough and finish, groove and
cutoff, are usually mounted radially with respect to the part. The cutting
tool is usually a ceramic insert mounted in a tool post designed for the
specific shape and size insert.
4
Face Groove
Face groove tools are mounted axially from the part.
Tool
5
Turret
The turret holds and moves the tools. To change tools, the turret unlocks,
rotates to present the active tool to the work piece, and then locks again.
Care must be taken that the turret is away from the part so that none of
the tools collide with the part as the turret indexes.
6
Boring Bar
A boring bar is used to create a precision size and finish hole through the
bore of the part. These are mounted axially with the spindle
7
8
Live Tool
A "live tool" is a tool that rotates, being driven by a mechanism in the
(Radial
holder. Radially mounted live tools are used for cross drilling or milling
Mount)
on the diameter of the part.
Live Tool
Axial mounted live tools mill or drill on the face of the part.
(Axial
Mount)
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SolidCAM Turning
SolidCAM offers you the following types of turning operations:
Figure 4. 4 Turning Operation Types
a. Face Turning Operation
Facing is the process of removing material from the end of a workpiece to produce a flat
surface. The principal working direction is the X-axis direction.
Figure 4.5 Face Turning
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b. Turning Operation
This operation is one of the most basic machining processes. That is, the part is rotated
while a single point cutting tool is moved parallel to the axis of rotation.. The resulting tool
path can either use the turning cycles of the CNC-machine, if they exist, or it can generate
all the tool movements. If the tool movements are generated by the program, then minimum
tool movements length is generated taking into account the material boundary in the
beginning of the particular operation. The profile geometry is adjusted automatically by
the program, if needed because of the tool shape, to avoid gouging of the material.
Figure 4.6 Turning Operation
c. Drilling Operation
This operation enables you to perform a drilling action along the rotation axis. A drill enters
the workpiece axially through the end and cuts a hole with a diameter equal to that of the
tool. There is no geometry definition for this type of operation since it is enough to define
the drill start and end positions.
Figure 4.7 Drilling Operation
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d. Threading Operation
Threading is the process of creating a screw thread.. The threading can be either
longitudinal (internal or external) or facial. This operation can be used only if the CNCmachine has a thread cycle. SolidCAM outputs the tool path for the threading exactly with
the same length as the defined geometry without any checking for material collision.
Figure 4.8 Threading Operation
e. Grooving Operation
This operation enables you to perform a groove either on a longitudinal geometry (internal
or external) or a facial geometry. A single-point turning tool moves radially, into the side
of the workpiece, cutting a groove equal in width to the cutting tool. Multiple cuts can be
made to form grooves larger than the tool width and special form tools can be used to create
grooves of varying geometries.The resulting tool path can either use a single machine
cycle, generate all the tool movements (G0, G1) or generate several machine cycles.
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Figure 4.9 Grooving Operation
f. Angle Grooving Operation
This operation enables you to perform inclined grooves. The geometry defined for this
operation must be inclined relative to the Z-axis of the CAM-Part Coordinate System. The
Tool angle parameter enables you to adjust the angle of the tool cutting the material.
Figure 4.10 Angle Grooving Operation
g. Cutoff Operation
Cutoff operation is use to create deep grooves which will remove a completed or partcomplete component from its parent stock and this operation can enables to produce flat
surface. The cutting can be performed using CNC-machine cycles; chamfers and fillets can
also be generated.
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Figure 4.11 Cutoff Operation
h. Balanced Rough Operation
This operation enables you to work with two tools performing roughing cuts at the same
time. The Master submachine and Slave submachine should include the same Table.
Figure 4.12 Balanced Rough Operation
i. Manual Turning Operation
This operation enables you to perform turning according to your own geometry regardless
of a stock model, target model, or envelope.The Reverse cutting path option enables you
to machine undercuts effectively.
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Figure 4.13 Manual Turning Operation
j. Simultaneous Turning Operation
This operation enables you to perform machining of curve-shaped tool paths using
tilting capabilities of tools with round inserts. The tool tilting is defined by specifying
lines that indicate the tool vector change. This operation is useful for machining of
undercut areas in a single machining step.
Figure 4.114 Simultaneous Turning Operation
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Labwork
The following steps for turning process will be followed:
A. Setting Process.
1. Open the part in SolidWorks software.
2. On the SolidCAM menu, select New and then choose Turning.
3. SolidCAM is started, and the New Turning Part dialog box is shown below.
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New Turning Part dialog box SolidCAM enables you to create a new CAMPart using one of the following options:

External mode in this mode, the part you create is saved in SolidCAM
format (*.prt, *.prz).

Internal mode in this mode, the part you create is saved inside
SolidWorks part (*.sldprt, *.sldasm)
4. Define Coordsys Option. Start the Coordinate System definition Click the Define button
in the Coordinate System area to define the Machine Coordinate System.
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With the Select Face mode choosen, click on the model face as shown. Make sure that the
Center of revolution face option is chosen. With this option, the origin is placed
automatically on the axis of revolution face.
Click Change to opposite to change the Z-axis direction to the opposite along the revolution
axis.
5. Click the Stock button, the Model dialog box is displayed. This dialog box enables you to
define the stock model of the CAM-Part to be machined.
In the Offsets dialog section, define the following offsets:

Set +Z to 2 to define the front offsets from the model.
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6. In the Turning Part Data dialog box, click the Target button. The Model dialog box is
displayed. This doalog box enables you to define a 3D Model for the Target.
Make sure that in the Type section Both is selected to consider both surfaces and solids for
Target model.
Click on the solid body, the wireframe model is displayed. Confirm the dialog box with
.
In the process of the Target model definition, SolidCAM creates the Envelope sketch in
the CAM component of the CAM-Part assembly. The Envelope sketch is used later for
the machining geometry definition.
7. Click
in the Turning Part Data dialog box to save the CAM-Part data.
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B. Machining Processes
 Face turn operation
1. Select the Face button from the Turning menu on the SolidCAM Operations. The face
turn dialog box is displayed.
2. Define the geometry. Choose Wireframe option in the geometry section. Click the New
icon
.
The Geometry dialog box is displayed. Make sure that the default Curve mode is chosen,
and select the sketch segments as shown. Confirm the chain definition with the Accept
chain
button.
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In the Edit Geometry section, click the Modify Geometry button. In the Start
Extension/trimming and End Extension/trimming section set to Auto extend to
stock.
3. Define the tool. Switch to the Tool page and click the Select button. Click the Add
Turning Tool and choose the Ext, Rough from the solid tools.

Set the tool holder width (A) value to 25.

Set the tool height (D) value to 55.

Set the tool tip angle (a°) value to 80.

Set Cutting edge direction to Left
and choose the Mounting type as shown
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4. Define the technology. Choose the front
option in the mode area, and make sure that
the Rough option is selected. In the Rough type, select the Smooth option.
5. Click the Save & Calculate, and the click Simulate button. Switch to Turning page for
diplay the 2D simulation of the turning tool path. Click the Play button, and the
simulation begin.
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Switch to SolidVerify page to view the tool path in 3D Model, the click Play button.
Rotate the model with the mouse wheel.
 Turning Operation
1. Select the Turning button from the Turning menu on the SolidCAM Operations. The
turning dialog box is displayed.
2. Click the New icon
in the Geometry page, and select the sketch segment as shown.
Make sure that the default Curve mode is chosen.
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Choose point to point option. It enables you to connect the specified points with a straight
line. Click on the sketch point as shown, and the linear geometry segment is defined.
Switch back to Curve mode and pick the rest of the sketch entities. Confirm the chain
definition with
button.
3. Use the tool defined in the previous operation. Click the Select button in the Tool page to
choose the tool from the Part Tool Table. Choose the Tool #1 and click Select.
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4. Define the Technology. Choose the Long external
option in the Mode area. In the
Work type, use the default Rough option.
In the Rough tab, choose Smooth for Rough Type and set the Step down value to 2. In
the Rough offset area, choose Distance option and set value to 0.5.
In the Semi-finish/finish tab, select the ISO-Turning method in Finish section and
choose Entire geometry from Finish on area.
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5. Click the Save & Calculate, and the click Simulate button.
 External Grooving operation
1. Select the Grooving button from the Turning menu on the SolidCAM Operations.
The grooving dialog box is displayed.
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2. Click the New icon
in the Geometry page, and select the sketch segment as shown.
Confirm the chain definition with the Accept chain
button.
3. Define the tool. Switch to the Tool page and click the Select button. Click the Add
Turning Tool and choose the Ext. Groove from the solid tools.

Set the width of the tool holder (A) to 25

Set the distance (B) to -8

Set the height of the tool tip (C) to 10

Set the lower width of the tool tip (G) to 3

Set the lengths of the tool tip cutting edges (D1 and D2) to 7

Set the tool tip angles a° and b° to 0

Set the nose radius Ra to 0.2

Set Cutting edge direction to Left
and choose the Mounting type as shown
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4. Define the technology. Choose the Long external
option in the Mode area. In the
Work type, use the default Rough option.
Choose the distance option in rough offset area and set to 0.5. In the Step over area, set
the value to 2.
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Switch now to Semi-finish/Finish tab. Make sure that the ISO-Turning method option
is chosen in the Finish area.
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5. Click the Save & Calculate, and the click Simulate button.
 Angled Grooving Operation
1. Select the Angled Grooving button from the Turning menu on the SolidCAM
Operations. The angled grooving dialog box is displayed.
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2. Click the New icon
in the Geometry page, and select the sketch segment as shown.
Confirm the chain definition with the Accept chain
button.
3. Define the tool. Switch to the Tool page and click the Select button. Click the Add
Turning Tool and choose the Ext. Groove from the solid tools. Click Advanced button
in top right corner to display the Mounting dialog box. Click
to choose orientation
as shown. Set the additional parameter to -45 to tilt the tool.
Define the following parameters:

Set the width of the tool tip (G) to 2

Set the distance the tool tip extends beyond the tool tip carrier (C) to 10

Set the cutting edge length (D1,D2) to 4

Set the tool nose (Ra) to 0.2

Set the Cutting edge direction to Left
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4. Define the technology. Choose Long External option in Mode area. Make sure that the
Rough option is chosen in the Work type area.
Choose Constant in Step down section and set value to 0.5. In the Step over area set
value to 2. Make sure that the Distance is choosen in Rough offset area and set to 0.5.
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In Semi-finish/finish tab, choose ISO-Turning method in finish area.
5. Click the Save & Calculate, and the click Simulate button
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 Drilling operation
1. Select the Drilling button from the Turning menu on the SolidCAM Operations. The
drilling dialog box is displayed.
2. Define the tool. Switch to the Tool page and click the Select button. Click the Add
Turning Tool and choose the Drill.

Set the D parameter to 15.

Set the A parameter to180.

Set the CL parameter to 90.
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3. Define the drill start position. Switch to the Technology page of Drilling Operation dialog
box. Click on the front face of the part as shown. Confirm this dialog box with
button.
4. Define the drill end position. Click the Drill end button in the Position area. Click on the
back face of the part. Confirm this dialog box with
button.
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In the Depth type section, select the Full diameter option. Click the Drill start button in
the position area
Change to integer number for more accurate result.
5. Click the Save & Calculate, and the click Simulate button.
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 Internal Turning operation
1. Select the Turning button from the Turning menu on the SolidCAM Operations. The
turning dialog box is displayed.
2. Click the New icon
in the Geometry page, and select the sketch segment as shown.
3. Define the tool. Switch to the Tool page and click the Select button. Click the Add
Turning Tool and choose the Int. Rough from the solid tools.

Set the tool holder width (A) value to 5.

Set the width of the turret (F) value to 15.

Set the tool nose radius (Ra) to 0.2.

Set Cutting edge direction to Left
and choose the Mounting type as shown
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4. Define the technology. Choose the Long internal
option in the mode area. In the
Work type area, choose the Rough option.
In the Rough tab, choose Smooth for Rough Type and set the Step down value to 1. In
the Rough offset area, choose Distance option and set value to 0.5.
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Choose the ISO-Turning method for finish in the Semi-finish/finish tab. In the finish on,
click Entire geometry.
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5. Click the Save & Calculate, and the click Simulate button.
 External Threading Operation
1. Select the Grooving button from the Turning menu on the SolidCAM Operations.
The grooving dialog box is displayed.
2. Click the New icon
in the Geometry page, and select the sketch segment as shown.
Confirm the chain definition with the Accept chain
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3. Define the tool. Switch to the Tool page and click the Select button. Click the Add
Turning Tool and choose the Ext. Thread from the solid tools.

Set Cutting edge direction to Left
and choose the Mounting type as shown
4. Define the technology. Choose Long External option in Mode area. Make sure that the
Multiple option is chosen in the Work type area and set the step down to 0.2.
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Switch to Data tab, Set value to 1.5 in Pitch unit. In the Minor diameter set to 56.
Choose Yes under External finish and Thread finish.
5. Click the Save & Calculate, and the click Simulate button.
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5th MODULE
NUMERICAL CONTROL CODE
Objective
1. Students are able to understand principal of NC-Code
2. Students are able to understand NC-code of milling operation
3. Students are able to understand NC-code of lathe operation
Tools
1. Computer
Basic Theory
Introduction
Today, along with the rapid advances in technology, the process of turning, drilling, milling,
and other conventional machining processes are no longer conducted or controlled manually,
but it use a computer. Such device, called CNC (Computer Numerical Control). CNC is a
machine controlled by a computer using a numerical language (movement commands that use
numbers and letters) in the process of operation.
Figure 5. 1 CNC Machine Analogy
We can analogize the CNC machine as a printer. When we are going to make an article, the first
thing we do is made up in the computer first, then when it has finished, we will print the article
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that we have made using the printer machine. Similarly, when we are going to make a product,
the first thing we do is creating an image of the design on the computer, and when the design
has been finished then we will print the design using the CNC machine. Before printing, the
design must be translated into machine language called NC-code
Type of CNC
Machine
In a medium and large industries we will found the use of CNC machines in favor of the
production processes. Broadly speaking, the CNC machines are divided into two kinds, they
are:
a. 3-Axis/Fraise CNC machine (Milling Machine)
b. 2-Axis/Lathe CNC machines (Lathe Machine)
a. 3-Axis/Fraise CNC machine (Milling Machine)
Milling is the machining process of using rotary cutters to remove material from a work
piece advancing (or feeding) in a direction at an angle with the axis of the tool.
Figure 5. 2 Milling Operation
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These are the symbols of milling machine’s movement direction:
-
X axis for horizontal direction movements
-
Y axis for transverse direction movements
-
Z axis for vertical direction movements
Figure 5. 3 Milling Operation
b. 2-Axis/Lathe CNC machines (Lathe Machine)
Figure 5. 4 Lathe Operation
The definition of a lathe is a machine that shapes objects by rotating them while a shaping tool
such as a chisel is applied to its surface or in other reference it called turning process. A lathe
is a machine tool which turns cylindrical material, touches a cutting tool to it, and cuts the
material. The lathe is one of the machine tools most well used by machining. A lathe machine
can be used to create symmetrical shapes into a piece of wood, metal or other material.
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Figure 5. 5 Part of Lathe machine
Numerical Control Code
A machine with computer technology are controlled by a numerical code. A software to
translate form code language into movement axis are usually called machine Control Unit
(MCU). This language which called programming language for communication between
machine and operator using a numerical, alphabetical, and symbol. Programming language in a
CNC machine known as Numerical Control Code (NC-Code).
Below are the mostly used NC Code to operating a machine, these are:
a. G-Code
G-Code are used to command specific actions for the machine: such as movements of the
machine. A functions of G code are already in International Standardization.
G-code and simple definitions:
G00
Rapid traverse
G01
Linear interpolation with feed rate
G02
Circular interpolation (clockwise)
G03
Circular interpolation (counter clockwise)
G2/G3 Helical interpolation
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G04
Dwell time in milliseconds
G05
Spline definition
G06
Spline interpolation
G07
Tangential circular interpolation / Helix interpolation / Polygon
interpolation feed rate interpolation
G08
Ramping function at block transition / Look ahead "off"
G09
No ramping function at block transition / Look ahead "on"
G10
Stop dynamic block preprocessing
G11
Stop interpolation during block preprocessing
G12
Circular interpolation (cw) with radius
G13
Circular interpolation (ccw) with radius
G14
Polar coordinate programming, absolute
G15
Polar coordinate programming, relative
G16
Definition of the pole point of the polar coordinate system
G17
Selection of the X, Y plane
G18
Selection of the Z, X plane
G19
Selection of the Y, Z plane
G20
Selection of a freely definable plane
G21
Parallel axes "on"
G22
Parallel axes "off"
G24
Safe zone programming; lower limit values
G25
Safe zone programming; upper limit values
G26
Safe zone programming "off"
G27
Safe zone programming "on"
G33
Thread cutting with constant pitch
G34
Thread cutting with dynamic pitch
G35
Oscillation configuration
G38
Mirror imaging "on"
G39
Mirror imaging "off"
G40
Path compensations "off"
G41
Path compensation left of the work piece contour
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G42
Path compensation right of the work piece contour
G43
Path compensation left of the work piece contour with altered approach
G44
Path compensation right of the work piece contour with altered approach
G50
Scaling
G51
Part rotation; programming in degrees
G52
Part rotation; programming in radians
G53
Zero offset off
G54
Zero offset #1
G55
Zero offset #2
G56
Zero offset #3
G57
Zero offset #4
G58
Zero offset #5
G59
Zero offset #6
G63
Feed / spindle override not active
G66
Feed / spindle override active
G70
Inch format active
G71
Metric format active
G72
Interpolation with precision stop "off"
G73
Interpolation with precision stop "on"
G74
Move to home position
G81
Drilling to final depth canned cycle
G82
Spot facing with dwell time canned cycle
G83
Deep hole drilling canned cycle
G84
Tapping or Thread cutting with balanced chuck canned cycle
G85
Reaming canned cycle
G86
Boring canned cycle
G87
Reaming with measuring stop canned cycle
G88
Boring with spindle stop canned cycle
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b. M-Code
M-code are codes non-axis commands that used in CNC to define function of the machine.
In application functions of Numerical, alphabetical and symbol codes are various, depends
on the system and machine control type but still it used in a same principle.
M-code and simple definition:
M00
Unconditional stop
M01
Conditional stop
M02
End of program
M03
Spindle clockwise
M04
Spindle counterclockwise
M05
Spindle stop
M06
Tool change (see Note below)
M19
Spindle orientation
M20
Start oscillation (configured by G35)
M21
End oscillation
M30
End of program
c. A-Code
Alarm code (A-code) is a sign when machine found uncorrective program. This code help
to stop machining process automatically if there are not corrections. Furthermore this code
will decrease possibility of machine damage.
A-Code and Simple defivnition:
A00
Command G & M false
A01
Command radius M99 false
A02
X Value False
A03
F Value False
A04
Z Value False
A05
Less command M30
A06
Extreme spindle rotation
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A08
Disk full/empty
A09
Cannot found program
A10
Disk Locked
A11
Load Disk false
A12
False Checking
A13
Unit false in object
A14
unit false
A15
H rate False
A17
Subroutine program False
Absolute and Incremental
The addresses X, Y and Z within a program, when G90 (Absolute coordinates) is active, relate
to a coordinate position from the work piece datum (the zero position). The addresses X, Y and
Z within a program, when G91 (Incremental co-ordinates) is active, relate to the individual axis
movements required to reach the new position, from the last position reached by the tool.
Desciption
The example move illustrated above
can be written in two ways:
G90 Absolute co-ordinates selected
G01 Y60 F150 ;
G03 X60 Y100 R40 ;
G91 Incremental co-ordinates selected
G01 Y60 F150 ;
G03 X-40 Y40 R40 ;
Figure 5. 6 Absolut and Incremental Coordinates
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NC Code for Milling
b. Corner Rounding and Chamfering
Example:
Figure 5. 7 Example of Mill
Description
O1234 (Tittle)
T1 M6;
G00 G90 G54 X0. Y0. S3000 M3;
G43 H01 Z0.1 M08;
G01 Z-0.5 F20.;
G00
G90
G54
S
M3
G43
M08
G01
F
Y-5. ,C1.;
X-5. ,R1.;
Y0.;
G00 Z0.1 M09;
G53 G49 Z0.;
G53 Y0.;
M30;
C
R
G53
G49
M30
: Rapid Traverse
: Absolute positions commands
: Select work coordinate system
: speed of spindle
: turn spindle on in forward direction
: Path compensation left of the work
piece contour with altered approach
: Coolant On
: Linear interpolation with feed rate
: Feed rate in inches (mm) per
minute
: Chamfer
: Fillet
: Non-modal machine coordinate
selection
: G43/G44/G143 cancel
: Program end and reset
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c. Using the R address
The R-value defines the distance from the starting point to the center of the circle. Use a
positive R-value for radius of 180° or less, and a negative R-value for radius more than
180°.
Programming examples:
Figure 5. 8 Milling using R address
Desciption
G90 G54 G00 X-0.25 Y-.25
G01 Y1.5 F12.
G00
: Rapid traverse
G02 X1.884 Y2.384 R1.25
G90
: Absolute positions commands
G54
: Select work coordinate system
G01
: Linear interpolation with feedrate
F
: Feedrate in inches (mm) per minute
R
: Diameter
G02
: Circular interpolation (clockwise
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NC Code for Lathe
a. G70 FINISHING CYCLE
Figure 5. 9 G70 Finishing Cycle
The G70 Finishing cycle can be used to finish to cut paths that are rough cut with stock removal
cycles such as G71, G72, and G73, but it can be used alone. The G70 requires that a beginning
block number (P code) and an ending block number (Q code) be specified.
G71 and G72 are similar canned cycles with regard to tool nose compensation. The finishing
and rough finishing passes of G71 and G72 recognize tool nose compensation; however, the
roughing pass of these two G codes does not. The template below can be applied to either G71
or G72.
(G70 P_Q_F_)

P = Starting blok (N Blok)

Q = Ending blok (N Blok)

F = Feed rate (mm/rev)
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Example :
Figure 5. 10 Example of Lathe
Description
O00005
(Example 1)
T101;
(Select tool)
G97 S1000 M03;
(Spindle speed 1000 RPM)
G00 G54 X40. Z2.;
(Rapid to start point)
G70 P1 Q2 F0.15;
(Rough P to Q using G70, feedrate 0.15)
N1 G00 X10;
(Starting block with rapid to X10)
G01 Z-5;
(Linear interpolation motion to Z-5)
G03 X20. Z-10. R5.;
(CCW circ.interpolation radius 5)
G01 Z-15.;
X25. Z-20;
Z-25.;
G02 X35. Z-30. R5.;
(CW circ.interpolation motion radius 5)
N2 G01 X40,;
(Ending block, linear motion to X40)
G28 U0;
(Back to starting point)
M05;
(Spindle stop)
M30;
(Program End)
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b. G71 O.D./I.D. STOCK REMOVAL CYCLE
Figure 5. 11 G71 Stock Removal
This canned cycle will rough out material on a part given the finished part shape. All a
programmer needs to do is to define the shape of a part by programming the finished tool path
and then submitting the path definition to the G71 call by means of a PQ block designation.
Any feeds, spindle speeds or tools within the block defining the path are ignored by the G71
call. Any F, S or T commands on the G71 line or in effect at the time of the G71, are used
throughout the G71 roughing cycle. Usually, a G70 call to the same PQ block definition is used
to finish the shape using the programmed feeds, speeds, tools and offsets defined within the PQ
block definition.
(G71 P_Q_U_W_D_F_)

P = Start number of blok (N Blok)

Q = End number of blok (N Blok)

U = Finishing allowance, x-axis direction, diameter (mm)

W = Finishing allowance, z-axis direction

D = Depth of cut (mm)

F = Feed rate (mm/rev)
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ID Turning
Example :
Figure 5. 12 Ilustration of ID Turning
Figure 5. 13 Example of ID turning
O00002;
T101;
G97 S1000 M03;
G00 G54 X0. Z2.;
G71 P3 Q4 U0.1 W0.1 D0.2 F0.15;
N3 G00 X40.;
G01 Z-5.;
OD Turning
X30. Z-10.;
Example
:
Z-15.;
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G3 X25. Z-20. R5.;
G01 Z-25.;
N4 G01 X0.;
G28 U0;
M05;
M30;
OD Turning
Example :
Figure 5.13 Ilustration of OD Turning
Figure 5. 144 Example of OD turning
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OD Turning
Example :
O00001
T101;
G97 S1000 M03;
G00 G54 X40. Z2.;
G71 P1 Q2 U0.1 W0.1 D0.2 F0.15;
N1 G00 X10.;
G01 Z-10.;
G03 X20. Z-15. R5.;
G01 Z-20.;
X25. Z-25.;
Z-30.;
G02 X35. Z-35. R5.;
N2 G01 X40.;
G28 U0;
M05;
M30;
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Labwork
Please fill the blank !
A. Milling
1. Milling (Chamfer & Fillet)
Study Case 1
In this case use tool number 1, absolute datum, spindle speed 1000 rpm, Z ( clearance) 0.1.
Figure 5.16 Labwork Milling
O1234 (Tittle)
T1 M6;
G__ G__ G__ X_. Y_. S___ M_;
G__ H01 Z__ M__;
G__ Z-0.5 F20.;
___. ,__.;
___. ,__.;
__.;
G_ _ Z_._ M_ _;
___ ___ Z_.;
___ Y_.;
___;
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B. Lathe
1. Finishing Cycle
Study Case 1
In this case, we use tool number 1, with spindle speed 1000 rpm. The finishing allowance of xaxis and z-axis in this process is 0.1 and 0.1. And the depth of cut is 0.2, while the feed rate is 0.15
mm/rev.
Figure 5.27 Labwork Finishing Cycle
O00005
T101;
G97 S1000 M03;
G00 G54 X40. Z2.;
G70 P1 Q2 U0.1 W0.1 D0.2 F0.15;
N1 G00 X10;
G__ X__. Z__. ;
Z___. ;
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G__ X__. Z___. R_. ;
G__ Z__. ;
G__X __. Z___. R__. ;
N2 G01 X40,;
G28 U0;
M05;
M30;
2. OD Removal Stock
Study Case 2
In this case, we use tool number 1, with spindle speed 700 rpm. The finishing allowance of x-axis
and z-axis in this process is 0.1 and 0.2, and the depth of cut is 0.3, while the feed rate is 0.1
mm/rev.
Figure 5.38 Labwork Finishing Cycle
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O00005
T101;
G__ S____ M__;
G__ G__ X__. Z__.;
G__ P_ Q_ U_._ W_._ D_._ F_._;
N2 G__
X__.;
___ ___.;
___ ___. ___. __.;
___ __. ;
__. __.;
___ ___. ____.
__.;
N3 G01 X40,;
G28 U0;
M05;
M30;
3. ID Stock Removal
Study Case 3
In this case, we use tool number 1, with spindle speed 1200 rpm. The finishing allowance of xaxis and z-axis in this process is 0.2 and 0.2, and the depth of cut is 0.3, while the feed rate is 0.15
mm/rev.
Figure 5.49 Labwork Finishing Cycle
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O00002;
T101;
___ _____ ___;
___ ___ __. __. ;
___ __ __ __._ __._ __._ _.__;
__ ___ ___.;
___ ____.;
___ ___. ___. __. ;
___ ____.;
___. ____.;
__ ___ __.;
___ __;
___;
___;
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6th MODULE
MACHINING PROCESS - MILL
Objective
1. Students are able to understand the principal of mill processing
2. Students are able to recognize the variety of HAAS Control Simulator keys
3. Students are able to understand about offset on CNC Milling Machine by using HAAS
Control Simulator
4. Students are able to manually create and simulate Numerical Control Code (mill process
program) by using HAAS Control Simulator
Tools
1. Haas Control Simulator version 3.4
Basic Theory
Milling
Milling is the machining process of using rotary cutters to remove material from a work piece
advancing (or feeding) in a direction at an angle with the axis of the tool (Brown and Sharpe
1914). It covers a wide variety of different operations and machines, on scales from small
individual parts to large, heavy-duty gang milling operations. It is one of the most commonly
used processes in industry and machine shops today for machining parts to precise sizes and
shapes.
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Types of Milling Machine
Types of milling machines based on the mill orientation
Mill orientation is the primary classification for milling machines. The two basic configurations
are vertical and horizontal. However, there are alternate classifications according to method of
control, size, purpose and power source.
a. Vertical mill
A turret mill has a stationary spindle and the table is moved both perpendicular and parallel
to the spindle axis to accomplish cutting. The most common example of this type is the
Bridgeport. Turret mills often have a quill which allows the milling cutter to be raised and
lowered in a manner similar to a drill press. This type of machine provides two methods of
cutting in the vertical (Z) direction: by raising or lowering the quill, and by moving the
knee. In the bed mill, however, the table moves only perpendicular to the spindle's axis,
while the spindle itself moves parallel to its own axis.
Figure 6.1 Vertical milling machine
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b. Horizontal Mill
A horizontal mill has the same sort of x–y table, but the cutters are mounted on a horizontal
arbor across the table. Many horizontal mills also feature a built-in rotary table that allows
milling at various angles; this feature is called a universal table. While end mills and the
other types of tools available to a vertical mill may be used in a horizontal mill, their real
advantage lies in arbor-mounted cutters, called side and face mills, which have a cross
section rather like a circular saw, but are generally wider and smaller in diameter. Because
the cutters have good support from the arbor and have a larger cross sectional area than an
end mill, quite heavy cuts can be taken enabling rapid material removal rates. These are
used to mill grooves and slots. Plain mills are used to shape flat surfaces. Several cutters
may be ganged together on the arbor to mill a complex shape of slots and planes. Special
cutters can also cut grooves, bevels, radii, or indeed any section desired. These specialty
cutters tend to be expensive. Simplex mills have one spindle, and duplex mills have two.
It is also easier to cut gears on a horizontal mill. Some horizontal milling machines are
equipped with a power-take-off provision on the table. This allows the table feed to be
synchronized to a rotary fixture, enabling the milling of spiral features such as hypoid
gears.
Figure 6.2 Horizontal milling machine
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Based on both figures above, the main different between the vertical and the horizontal milling
machine is the spindle (spindle is the shaft to which the milling cutter is attached), the spindle of
the horizontal milling machine is horizontal and in the vertical milling machine it is vertical.
Classification of Milling Processes
Two main classifications of milling processes are peripheral milling and face milling. Here are
some differences between those two milling processes:
(1) Peripheral milling :

Cutter axis is parallel to surface being machined

Cutting is accomplished by the peripheral teeth of the milling cutter

Mostly performed on a horizontal milling machine
(2) Face milling :

Cutter axis is perpendicular to surface being milled

Cutting is accomplished by both the flat face of the cutter and the peripheral teeth of
the milling cutter

Mostly performed on a vertical milling machine
Figure 6.3 (a) Peripheral milling & (b) Face Milling
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CNC Machine Controller
The CNC controller is the brain of a CNC system. A controller completes the all important link
between a computer system and the mechanical components of a CNC machine. The controller's
primary task is to receive conditioned signals from a computer or indexer and interpret those
signals into mechanical motion through motor output. There are several components that make
up a controller and each component works in unison to produce the desired motor movement.
The word “controller” is a generic term that may refer to one of several devices, but usually
refers to the complete machine control system. This system may include the protection circuitry,
stepper or servo motor drivers, power source, limit switch interfaces, power controls, and other
peripherals. Owners, operators, designers, and builders of CNC devices should understand the
tasks performed by these components and how they affect machine performance. In this chapter,
HAAS Control Simulator will be explained more specifically.
Function of buttons on HAAS Control Simulator
a. General Machine Keys
Button
Table 6.1 General Machine Keys
Function
Power On
Turns CNC machine on.
Power Off
Turns CNC machine tool off.
Emergency Stop
Stops all axis motion, stops spindle, tool changer and
turns off coolant pump.
Jog Handle
Jogs axis selected, also may be used to scroll through
programs, menu items while editing and also altering
feeds and speeds.
Cycle Start
Starts program in run mode or graphics mode.
Feed Hold
Stops all axis motion. Spindle will continue to turn.
Reset
Stops machine, will rewind program.
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Control functions in Haas machine tools are organized in three modes, those are Setup, Edit and
Operation. Access Modes using the mode keys as follows:
-
Setup : ZERO RET, HAND JOG keys. Provides all control features for machine setup.
-
Edit : EDIT, MDI/DNC, LIST PROG keys. Provides all program editing, management,
and transfer functions.
-
Operation : MEM key. Provides all control features necessary to make a part
Figure 6.4 Keypad Operation
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b. Keyboard Introduction
The keyboard is divided into eight different sectors: Function Keys, Jog Keys, Override
Keys, Display Keys, Cursor Keys, Alpha Keys, Number Keys and Mode Keys. In addition,
there are miscellaneous keys and features located on the pendant and keyboard which are
described briefly the following pages.
 Function Keys
Button
Table 6.2 Function Keys
Function
F1 F4
Perform different functions depending on which mode the
machine is in. Example in offsets mode F1 will directly enter
value that you give it into to offset register.
Tool Offset Measure
Will take machine Z position readout at bottom of offset screen
and load it in to the highlighted tool offset register.
After pressing Tool Offset Measure button in a set up this will
Next Tool
select the next tool and make a tool change.
Releases tool from spindle in MDI, Zero Return or Handle
Tool Release
mode. A button on the front of the spindle will do the same
thing.
Part Zero Set
Records work coordinate offsets into the highlighted register.
 Jog Keys
Button
Table 6.3 Jog Keys
Function
Chip FWD (Chip Auger Forward)
Turns the optional chip auger in a direction that removes
chips from the work cell.
Chip Stop (Chip Auger Stop)
Stops auger movement.
Chip REV (Chip Auger Reverse)
Turns the chip auger in reverse.
CLNT UP (Coolant Up)
Pressing this key will position the coolant stream one
position higher.
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CLNT DOWN (Coolant Down)
Pressing this key positions the coolant stream one
position lower. Coolant stream position will appear in
tool length offset register when position is highlighted.
AUX CLNT (Auxiliary Coolant)
Turns on the optional Through-the-Spindle (TSC)
coolant (in MDI mode).
+X, -X (Axis)
Selects the X axis for continuous motion when depressed.
+Y, -Y (Axis)
Selects the Y axis for continuous motion when depressed.
+Z, -Z (Axis)
Selects the Z axis for continuous motion when depressed.
+A, -A (Axis)
Selects the A axis. This key selects the B axis when used
with the SHIFT key if the machine is configured with a
fifth-axis option.
 Override Keys
The overrides are at the lower right of the control panel. They give the user the ability
to override the speed of rapid traverse motion, as well as programmed feeds and spindle
speeds.
 Display Keys
Table 6.4 Display Keys
Button
Function
PRGM/
Selects the active program pane (highlights in white). In MDI/DNC
CONVRS
mode pressing a second time will allow access to VQC (Visual
Quick Code) and IPS (Intuitive Programming System).
POSIT (Position)
Selects the positions display window (lower middle). Repeated
pressing of the POSIT key will toggle through relative positions in
the Memory Mode. In Handle Jog mode all four are listed together.
OFFSET
Selects one of two offsets tables: Tool Geometry/Wear and Work
Zero Offset.
WRITE/
will add the number in the input buffer to the selected offset, and the
ENTER
F1 key will replace the selected offset with the number entered into
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the input buffer. Offsets can also be entered using TOOL OFSET
MEASUR and PART ZERO SET
CURNT
Ten different pages; use PAGE UP and PAGE DOWN
COMDS
1. Operation Timers displays Power-On Time, Cycle Start Time,
Feed Cutting Time. Hitting ORIGIN will clear any display that
is highlighted by the cursor.
2. Real time clock and date
3. System Variables, for machines with Macro Programming.
4. All Active Codes, displays current and modal command values.
5. Position information: Machine, Distance to Go, Operator,
Work Coordinate.
6. Tool life, displays the usage of each tool. An alarm can be set
for the number of times you want that tool to be used, and when
that condition has been met (that is, the tool has been used the
set number of times), the machine will stop, with an alarm for
you to check the condition of that tool. Pressing ORIGIN will
clear the cursor-selected display, and pressing ORIGIN when the
cursor is at the top of a column will clear the whole column.
7. Tool Load displays the Tool Load Max % of each tool being
used. You can use the Limit% column to set the maximum
spindle load for a particular tool. When that condition has been
met (the tool has reached maximum load), the machine will stop
for you to check the condition of that tool. Pressing ORIGIN
will clear the cursor-selected display, and pressing ORIGIN
when the cursor is at the top of a column will clear the whole
column. Setting 84 determines the Overload Action when this
limit is met.
Also vibration loads may be entered.
8. Maintenance times for various items may be loaded.
9. Advanced Tool Management (Optional)
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10. Tool Pot Table: Gives information on which tool is in which Pot.
Refer to Automatic Tool Change section on information on how
to use this table.
ALARM/
Displays messages and current active alarms. Press right arrow key
MESGS
gives alarm history. Press right arrow key again goes to the Alarm
Viewer Page. Enter alarm number and press write will give detailed
information on a particular alarm code.
PARAM/
Lists machine parameters that are seldom-modified values which
DGNOS
change the operation of the machine. These include servo motor
types, gear ratios, speeds, stored stroke limits, lead screw
compensations, motor control delays and macro call selections. All
of these are rarely changed by the user and should be protected by
Setting
7,
PARAMETER
LOCK.
A
second
press
of
PARAM/DGNOS will show the diagnostics display. The PAGE
UP and PAGE DOWN keys are then used to select one of two
different pages. This display is for service diagnostic purposes, and
the user will not normally need them.
SETNG/
Displays settings - machine parameters and control functions that
GRAPH
the user may need to turn on and off or change to suit specific needs.
HELP/
Will bring up a help POP UP relevant to the screen you are in. This
CALC
provides information only pertaining to that screen. Pressing the
HELP/CALC button again brings up a tabbed menu. With
tabulated screens highlighting tab and pressing WRITE/ENTER
key will open up respective tab. Pressing the CANCEL key will
close the tab.
Milling and Tapping
Help you solve values for feed rates SFM, RPM, and chip load under
different conditions.
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 Cursor Keys
Cursor Keys the cursor keys are in the center of the control panel. They give the user
the ability to move to and through various screens and fields in the control. They are
used extensively for editing and searching CNC programs. They may be arrows or
commands.
Table 6.5 Cursor Keys
Button
Function
Up/Down
Moves up/down one item, block or field.
Page Up/
Used to change displays or move up/down one page when viewing a
Down
program.
HOME
Will move the cursor to the top-most item on the screen; in editing, this
is the top left block of the program.
Will take you to the bottom-most item of the screen. In editing, this is the
END
last block of the program.
 Alpha Keys
The Alpha Keys allow the user to enter the 26 letters of the alphabet along with some
special characters. Depressing any Alphabet Key automatically puts that character in
the Input Section of the control (lower left-hand corner).
Table 6.6 Alpha keys
Button
Function
SHIFT
provides access to the yellow characters shown in the upper left corner of
some of the alphanumeric buttons on the keyboard. Pressing SHIFT and
then the desired white character key will enter that character into the input
buffer.
EOB
enters the end-of-block character, which is displayed as a semicolon on
the screen and signifies the end of a programming block. It also moves
the cursor to the next line.
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These keys are used to define negative numbers and give decimal
( ) and (.)
posistion.
These symbols are accessed by first pressing the SHIFT key and then the
+=#*[]
key with the desired symbol. They are used in macro expressions (Haas
option) and in parenthetical comments within the program.
These are additional symbols, accessed by pressing the SHIFT key, that
,?%$!&@:
can be used in parenthetical comments.
 Numeric Keys
The Numeric Keys allow the user to enter numbers and a few special characters into
the control. Depressing any number key automatically puts it into the Input Section of
the Control.
Button
Table 6.7 Numeric Keys
Function
Cancel
The Cancel key will delete the last character put into the
Input Section of the control display.
Space
Is used to format comments placed into the Input Section of
the control display.
Write/
General purpose Enter key. It inserts code from the input
Enter
section into a program when the program display is in EDIT
mode.
With
offsets
pages
active,
pressing
the
WRITE/ENTER key adds a number in the Input Section to
the highlighted cell. Pressing the F1 key will input the
number into the cell.
-
The (Minus Sign) is used to enter negative numbers.
.
The (Decimal Point) is used to note decimal places.
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 Mode Keys
Mode keys set the operational state of the machine tool. Once a mode is set the keys
to the right may be used. The current operation mode of the machine is displayed at
the top thin pane of the CRT
Button
Table 6.8 Mode Keys
Function
EDIT
The edit mode is used to make changes in a program stored
in memory. When you press EDIT two panes appear at the
top of the screen. In the left pane the active program appears.
In the right an inactive program appears or the select
program screen appears. On the bottom left a editor help
pane appears and on the right a clipboard pane. Editing may
be performed in either the active or inactive panes. Pressing
EDIT toggles between the two panes, (changes background
to white). To call up a program from memory and put it in
one of the edit panes press SELCT/PROG. Highlight the
program desired by using the up or down cursor buttons and
press WRITE/ENTER.
INSERT
Enters commands keyed into the input panel in lower left
pane of CRT after the cursor highlighted word in a program.
ALTER
Highlighted words are replaced by text input into the input
panel.
DELETE
Highlighted words are deleted from a program.
UNDO
Will undo up to the last 9 edit changes.
F1 KEY
While in the edit mode pressing F1 will bring up an edit pop
up window. Using the sideways cursor buttons will toggle
thru HELP, MODIFY, SEARCH, EDIT AND PROGRAM
MENUS. The up and down buttons will cursor thru the
different options in each of the above.
MODIFY
Gives options on changing line numbers.
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SEARCH
Will perform a search and gives the option of replacing text.
EDIT
Gives option of cutting or copying and pasting to a clipboard
and to another program.
PROGRAM
Gives options of creating new program, selecting a program
from list to edit, duplication of programs, switching from
left to right side of window panes.
Background Edit When a program is being run pushing the edit will bring up
the Background Edit pane in the Main Display Pane. Simple
edits may be performed on the program that is being run or
another program. The edits on the running program will not
take place until after the current cycle has completed.
MEM
The memory mode is the mode used when running the
machine and making a part. The active program is shown in
the Program Display Pane. Keys in the memory mode line
reflect different ways of running a part in memory. When
the keys to the right are depressed they will show up
highlighted in black on the bottom right of the CRT.
SINGLE
When depressed SINGLE BLOCK is highlighted in black
BLOCK
and will appear on the bottom of the CRT. When the
machine is in SINGLE BLOCK mode only one block of the
program is executed every time the cycle start button is
depressed. Used when first test running a program or
temporarily stopping a program when it is running.
DRY RUN
Used to check machine movement without cutting a part. In
dry run the machine runs at one feed rate. With the
availability of graphics which show visually what the
machine tool path is this mode is rarely used.
OPTION
When OPTION STOP is depressed program will stop at any
STOP
M01 which is in the program. Normally M01s are placed
after a tool is run in a program. When a job is being set up
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the operator may put machine in op stop mode to check
dimensions after every tool has completed cutting.
BLOCK
When this button is depressed any block with a slash (/) in it
DELETE
is ignored of skipped.
MDI
(MANUAL DATA INPUT mode) Usually short programs
DNC
are written in MDI but are not put into memory. DNC mode
allows large programs to be drip fed from a computer into
the control.
COOLNT
Turns coolant on and off manually.
ORIENT
Rotates and locks spindle to specific angle. Used when
SPINDLE
lining up tools where spindle orientation may be a issue such
as boring heads.
ATC FWD
Rotates turret to next tool and performs tool change - also
used to call up specific tools or pots. Enter tool number (T1)
and press ATC FWD.
HAND JOG
Puts machine in jog mode for set ups. Top values (.0001,
.001, .01, .1) represent distance traveled per click of jog
handle. Bottom values (.1, 1., 10., 100) represent feed in
inches/minute when jogging axis using jog buttons.
ZERO RET
On pressing position display becomes highlighted in Zero
Return mode.
ALL
Returns all axes to machine home similar in similar fashion
as a Power Up/Restart.
ORIGIN
Sets selected displays to zero or other functions.
SINGL
Returns a single axis to machine home. Select desired axis
(X, Y, or Z) then press Singl axis button.
Home/G28
Rapid motion to machine home; will make a rapid move in
all axes at once - may also be used for a rapid home in oneaxis. Press axis to home then G28. Caution must be used that
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fixtures or parts are out of the way before initiating this rapid
move to home.
SELECT
After highlighting a program from List Program with up or
PROG
down cursor pressing this button will place the program in
the Active Program Pane. This is the program that will run
the CNC machine in the Memory mode. Use in the Edit
mode in the Main Display will enter selected program in the
Main Display pane for editing.
SEND
Will send a selected program or programs out thru RS-232
serial port
ERASE
Will erase highlighted program or programs. A prompt will
PROG
appear asking if you want to delete selected program asking
for Y/N.
Setting Offsets
In order to accurately machine a work piece, the mill needs to know where the part is located
on the table. Jog the mill with a pointer tool in the spindle, until it reaches the top left corner of
the part (see the following illustration), this position is part zero. The value will be entered into
G54 on the Work Offset page. Offsets can also be entered manually by choosing one of the
offset pages, moving the cursor to the desired column, typing a number and pressing Write or
F1. Pressing F1 will enter the number in the selected column. Entering a value and pressing
Write will add the amount entered to the number in the selected column.
Typical Work Offset
Setup
1. Place the material in the vise and tighten.
2. Load a pointer tool in the spindle.
3. Press Handle Jog
4. Press .1/100. (B) (The mill will move at a fast speed when the handle is turned).
5. Press +Z (C).
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6. Handle jog (D) the Z-axis appoximately 1’’ above the part.
7. Press .001/1.(E) (The mill will move slow speed when the handle is turned).
8. Handle jog (D) the Z-axis approximately 0.2” above the part.
9. Select between the X and Y axes (F) and handle jog (D) the tool to the upper left corner of
the part (See the following illustration).
10. Press Offset (G) until the Work Zero Offset Pane is active.
11. Cursor (I) to G54 Column X.
12. Press Part Zero Set (J) to load the value into the X–axis column. The second press of the
part Zero Set (J) will load the value into the Y axis column.
CAUTION! Do Not Press Part Zero Set s third time; doing so will load a value into the Z-axis.
This will cause a crash or Z-axis alarm when the program is run.
Figure 6.5 Work Offset
Setting the Tool Offset
The next step is to touch off the tools. This defines the distance from the tip of the tool to the top
of the part. Another name for this tool length Offset, which is designed as H in a line of machine
code; the distance for each tool is entered into the Tool Offset Table.
1. Load the tool in the spindle.
2. Press Handle Jog (A).
3. Press.1/100.(B) (The mill will move at a fast rate when the handle is turned).
4. Select between the X and Y axes (C) and handle jog (D) the tool near the center of part.
5. Press +Z (E).
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6. Handle Jog (D) the axis approximately 1” above the part.
7. Press .001/.1 (F) (The mill will move at a slow rate when the handle is turned).
8. Place a sheet of paper between the tool and the work piece. Carefully move the tool down
to the top of the part, as close as possible, and still be able to move the paper.
9. Press Offset (G).
10. Press page up (H) until the page with “Coolant – Length – Radius at top and scroll to tool
numbe 1.
11. Cursor (I) to Geometry for position #1.
12. Press toll Offset Measure (J). This will take the Z position located in the bottom left of the
screen and put it at the toll number position.
CAUTION! The next step will cause the spindle to move rapidly in the Z axis.
13. Press Next Tool (K).
14. Repeat the offset process for each tool.
Tool length is measured from the tip
of the tool to the top of part with the
Z axis at its home position
Figure 6.6 Tool Offset
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Standard Operation of HAAS
a. How to turn on Haas Control Simulator
1. Connect Haas Control Simulator to energy
Figure 6.7 Simulator
2. Press Emergency Stop button before turn on the Simulator
Figure 6.8 Emergency Stop
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3. Press Power On (Green Button) button to turn on the Simulator
Figure 6.9 Power On
4. Press Left to Choose Mill Operation
Figure 6.10 Simulator Display
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5. Follow the instruction from the screen and wait until it ready to start, release Emergency
Stop button
Figure 6.11 Screen of Setup Zero
6. Press Reset to enable servos
Figure 6.12 Screen of enable servos
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7. Press Power Up Button, wait until the machine configure the position (x, y, z) machine
Figure 6.13 Screen of Zero all axes process
8. The Operation is ready to use
Figure 6.14 Screen of Operation ready to use
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b. How to turn off Haas Control Simulator
1. To turn off the simulator machine, press the Emergency Stop
Figure 6.15 Emergency Stop
2. Then, press Power Off Button (Red Button) and wait until the simulator turn off
Figure 6.16 Power Off
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Labwork Procedure
Tool and Work offsets must be set before an operation can be run. Enter values for each tool used
on the Setup screen. The tool offsets will be referenced when that tool is called in the operation.
On each of the following interactive screens the user is asked to enter data needed to complete
common machining tasks. When all the data has been entered, pressing “Cycle Start” will begin
the machining process.
a. Tool Offset
1. Press MDI DNC → OFFSET ( Tool Offset default = 0 )
2. Input Geometry (Length and Dia), Flutes, Actual Diameter, and Tool Type (depends
on the measurement)
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b. Work Offset
1. Press OFFSET ( Work Zero Offset default = 0 )
2. Input X Axis, Y Axis, Z Axis ( depends on the measurement )
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c. Facing Operation
Facing is an operation of machining the ends of a workpiece to produce a flat surface square
with the axis. In this labwork, a facing program will be made manually.
1. To access a list of programs that already exist in the internal memory, press LIST PROG →
choose “memory”, and then press ENTER.
2. Use the Cursor Keys or the Handle Jog to find some numbers of program that doesn’t
exist yet. To make a new program, type “O (alphabet) + the number of program that
haven’t exist yet” (ex: O40), and then press ENTER.
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3. Press EDIT to make or edit codes for the program, and then type the required codes (it’s
not necessary to use a SPACE), after writing a line of codes press WRITE/ENTER (to
delete a code before ENTER was pressed, press CANCEL, and to delete a code after
ENTER was pressed, press DELETE).
Here is the case :
o Work offset G54
o Tool = end mill (d=10 mm), tool number 3
o Workpiece length (y) = 250 mm, and width (x) = 200 mm
o Depth of face = 2 mm
o Tool clearance (a distance between workpiece and peripheral teeth of cutter) = 5 mm
o Spindle speed = 582 rpm
o Feedrate = 78,833 mm/minute
o Stepover = 100%
o R plane (a distance between workpiece and flat face of cutter) = 5 mm

First, make a subprogram, a feed program.
Note : Z value in line 4 = depth of face
X value in line 5 = – (tool clearance + 0.5 tool diameter)
Z value in line 6 = R plane
X value in line 7 = workpiece width + tool clearance + 0.5 tool diameter
Y value in line 9 = tool diameter * % stepover
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
Secondly, make a main program, a program that consists of a subprogram and another
required codes in it. Press LIST PROG to go back to the program list, and make a new
program like the previous step (step number 2 & 3), with a different number of
program.
Note : X value in line 4 = workpiece width + tool clearance + 0.5 tool diameter
Y value in line 4 = – (stock length – 0.5 tool diameter)
H value in line 6 = tool number
Z value in line 6 = R plane
P40 in line 7 means to call program number 40 (subprogram)
L25 in line 7 means the subprogram will loop for 25 times
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4. Press SETTING GRAPH, and then CYCLE START button to see the facing simulation
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5. Make a rapid move by using the size of workpiece as a reference, to see if the workpiece
have been eaten or not. Press EDIT, then write the following codes below after the 7th
line in main program, here are the codes for the case above :
G00 G90 X0 Y0 ;
Y-250. ;
X200. ;
Y0 ;
X0 ;
Note : The Y value in line 9 = - (workpiece length)
The X value in line 10 = workpiece width
6. See the simulation by following the step number 4
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Extra Labwork
Here is the second case :
o Work offset G54
o Tool = end mill (d=10 mm), tool number 3
o Workpiece length (y) = 160 mm, and width (x) = 100 mm
o Depth of face = 3 mm
o Tool clearance = 2 mm
o Spindle speed = 1200 rpm
o Feedrate = 500 mm/minute
o Stepover = 80%
o R plane = 3 mm
Fill the blank !

Sub Facing :
O000__ ;
(SUB FACING 2 FRI-XXX)
G90 ;
G00 ___ ;
G01 ___ ___ ;
G00 ___ ;
G00 ___ ;
G91 ;
G00 ___ ;
M99 ;
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
Main facing :
O000__ ;
(MAIN FACING 2 FRI-XXX)
___ M06 ;
G00 G90 ___ ___ ___ ;
___ M03 ;
G43 ___ ___ M08 ;
M98 ___ ___ ;
M09 ;
M05 ;
G28 G91 Z0 ;
G00 G90 ___ X0 Y0 ;
M01 ;
M30 ;
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7th MODULE
MACHINING PROCESS - LATHE
Objective
1.
Students are able to understand principal of lathe processing
2.
Students are able to understand about Numerical Control Code on Lathe Machine by
using HAAS Lathe Simulator
3.
Students are able to create and simulate NC code of lathe Processes by using HAAS Lathe
Simulator
Tools
1. HAAS Simulator Version 3.4
Basic Theory
Introduction
Turning is a machining process with a geometrically defined cutting edge, a rotational cutting
motion and an arbitrary transverse translatory feed motion. For kinematical classification, one
always takes into consideration the relative movement between the work piece and the tool.
Turning methods can be classified from various standpoints. For example different objectives
of the machining task lead to the distinction between finish and rough turning. In the case of
rough turning, a high material removal rate is reached. The objective is to realize a high level
of dimensional accuracy and surface quality via small cross-sections of undeformed chip. The
flexibility of this manufacturing process allows for economical use from prototype and mass
production. In the case of automated and NC operations, several tools can be engaged
simultaneously during the machining process in order to reduce manufacturing times and to
increase the material removal rate.
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Figure 7.1 Illustration
sketch of lathe process
Figure 7.2 Styles of insert holders
The turning tools of the various process variants are classified analogously to Figure 2 according
to the design of their tool holder.
Classification
a. Face Turning
Face turning is a turning method used to produce an even surface orthogonal to the axis of
rotation of the work piece. Process variants include, amongst others, transverse face turning
and transverse parting-off for sectioning workpiece components or the entire work piece
(Figure 7.3).
Figure 7.3 Process variants of face turning
The cutting path of all transverse face turning variants lies on an Archimedean spiral. In
the case of cylindrical face turning variants on the other hand, the cutting path is in the
shape of a coil (helical line). Face turning operations are usually carried out with automatic
lathes, especially in the case of small parts, which are manufactured from a bar. In
transverse parting-off operations, the tools are designed to be slender in order to minimize
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loss of material. Both minor cutting edges are tapered toward the tool shaft in order to avoid
jamming. Under heavy strain, the tools tend to clatter due to their geometric design. During
face turning processes, one must bear in mind that the cutting speed changes with the tool
diameter when machining with a constant rotation speed. On conventional lathes, a certain
cutting speed range is maintained, for example, by multiple, gradual adjustment of the
rotation speed to the machining diameter. In the case of lathes with continuous rotation
speed control, the cutting speed is kept constant.
b. Cylindrical Turning
Cylindrical Turning is used to produce a cylindrical surface that is coaxial to the axis of
rotation of the workpiece. The use of this method extends from finishing very small parts
(e.g. in the clock and watch industry) to heavy roughing forged turbine blades or drive
shafts for plant engineering (e.g. cement mills with lengths of up to 20 m).
The most important variants of cylindrical turning are longitudinal cylindrical turning and
centreless rough turning (Figure 4). Longitudinal cylindrical turning is the most common
method variant, which will be used to exemplify many different machining phenomena.
Centreless rough turning is cylindrical turning with several major cutting edges arranged
on a rotating tool. The feed movement is made by the workpiece and the rotation movement
by the tool. This combination leads to a very high material removal rate. This process
variant is predominantly used for removing oxide and roller coatings as well as the surface
cracks of rolling and forging blanks such as is required, for example, in the manufacture of
cold drawn steel.
Figure 7.4 Process variants of cylindrical turning
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c. Helical Turning
Helical turning is used to manufacture helical surfaces with profiling tools. Feed
corresponds to the pitch of the screw thread. Figure 5 shows a few important process
variants that fall under this category: thread turning, thread chasing and thread die
cutting.
In the case of thread turning, the thread is manufactured by only one profiled cutting
edge in several passes until the required thread depth is obtained. It is characteristic of
this process variant that the pitch is produced by the feed. On conventional lathes, the
translatory motion is mechanically linked to the rotation motion. In the case of
numerically controlled lathes, this link is made electronically.
Thread turning tools are available as both part and full profile tools. Part profile tools
can only be used when the workpiece is brought to the required external diameter
before thread turning, since only the pitch is cut and the external surface is no longer
machined. After thread turning, the depth of the thread must be checked. Full profile
tools on the other hand are shaped in such as way that the corresponding thread depth
is directly cut from the material so that the output workpiece must not be prepared
beforehand (Figure 7.5).
Figure 7.5 Process variants of helical turning
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Figure 7.6 Helical turning: part and full profile tools, chaser
d. Profile Turning
Profile turning is used to produce rotation-symmetrical workpiece shapes by
reproducing he tool profile. Profile turning variants are classified according to their
process kinematics. The most common methods, shown in Figure 7.7, are face profile
grooving, transverse profile grooving and transverse profile turning.
Figure 7.7 Process variants of profile turning
In the case of profile turning, tools made of both high speed steel and cemented
carbide are used. Profile tools made of high speed steel are very common, as they
are very tough, easy to manufacture and to regrind.
e. Form Turning
Form turning is used to produce workpiece shapes by controlling the feed movements.
Form turning is categorized as in Figure 7.8 into NC form turning, copy turning and
kinematic form turning.
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Figure 7.8 Process variants of form turning
In NC form turning, the feed movement is realized by electronically linked feed drives.
NC form turning is the state of the art today. Copy turning involves deriving the feed
movement from a reference shape, a moulding or a masterpiece. Pure copy turning was
developed further when machine tool controls were made available that could store a
contour that had once been applied. These are called teach-in processes.
Kinematic form turning was often used in the past to produce ball heads. In this case,
the feed axes were kinematically linked via a transmission. This process variant has
also been replaced by NC form turning.
f. Further Process Variants
Up to this point, selected process variants were basically explicated using the example
of external machining. In principle, these process variants can also be used for internal
machining as shown in Figure 9.
Figure 7.9 Internal turning
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When using internal turning to produce deep contours however, stability problems can
arise due to the long protrusion length of internal turning tools. For this reason, the
protrusion length and the shaft diameter, which depends on the size of the contour to
be machined, should be taken into consideration when selecting the cutting parameters.
Figure 7.10 shows some typical tools used in internal turning.
Figure 7.10 Internal turning: tool design (Source: Sandvik Coromant)
Type of Lathe Machine
Generally lathe machine has four types, these are; Conventional lathe, Specified Purpose Lathe,
Universal Lathe, and CNC Lathe.
a. Conventional Lathe mostly use in low to middle industries, such as workshop garage, and
home industry. Conventional lathe operated manually, and every conventional lathe have
different function. For example drilling machine cannot be used for facing lathe. Of all
Lathe mechine type, this one is the cheapest, but for routine using it would be increase
inaccurate and precission decrease because it works really depends on operators skill.
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Figure 7.11 Conventional Lathe
b. Specified purpose lathe, this type is designed for specific function of operating or working
material. Function of operation such as surface facing, shaping, drilling, etc. And specified
working material such as steel, copper, etc.
Figure 7.12 Sepcified lathe facing
c. Universal lathe, is a combination of many operation of lathe process in one machine, so it
can be handle more than one function on one machine. It able to create a finish product
from the beginning process of material until finishing it very usefull and efficient and
usually used in highscale industry.
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Figure 7.13 Universal Lathe
d. CNC lathe or Computer Numerical Control Lathe, is the most modern technology of
lathe. It using numerial code to control the machine and using supprt of computer
technology. For routine activity in turning process this machine is high accuracy and more
precisive because it seems copying one code to the next activity. CNC lathe is devide into
two purpose of machine, there are CNC Training Unit mostly used for training session for
preparing basic skill of operator and using soft metal as the work material and CNC
Production Unit is used for production way, mostly for highscale production capacity.
Figure 7.14 CNC Lathe HAAS ST20
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Component of CNC Lathe
There are several main parts of lathe with its own function:
Table 7.1 – Several Component of CNC Lathe
No
Name
Function
1
tool
A kind of borr or
knife in a machine
2
turret
A place to plug a
tool based on the
list or dimension
3
Collet
A tool to hold
working material
4
Chuck
A tool to hold
working material on
machining process
5
Holder
A tool to place an
eye of knife
6
Insert knife
An eye of knife to
inserted to holder
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No
Name
Function
7
Spindle
A machine part to
Picture
move / turn the
working material
while machining
process
Cartesian Coordinate
System
The first diagram we are concerned is called a number line. This number line has a reference
point zero that is called absolute zero and may be placed at any point along the line.
Figure 7.15 The Cartesian Coordinate System
The number line also has numbered increments on either side of absolute zero. Moving away
from zero to the right or to the top are positive increments. Moving away from zero to the left
or to the bottom are negative increments. We use positive and negative along with the
increment’s value to indicate its relationship to zero on the line.
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Absolute and Incremental Positioning
By using WORK and TOOL OFFSETS a common point on the part is designated as “PART
ZERO”. This is some point on our part that we can physically find. The programmer uses this
point as a base to write the intended movement of the tooling.
Programmers normally use the front end of our finish machined part as (Z Zero) and the
centerline of part as (X Zero).
There are two methods used by the programmer to “Steer” our machine. The first is
“ABSOLUTE POSITIONING”. Absolute means that X and Z code values are based on the
ZERO POINT on the part. If a diameter of 1.0000 inches is needed, it is input as X1.0000. If
the print requires facing a shoulder that is 3 inches back from the front of the part, Z-3.0000 in
input in the code. The letters X&Z represent ABSOLUTE POSTIONING.
The programmer has another tool available to him called “INCREMENTAL POSITIONING”.
This is movement based on where the machine is currently sitting. It is also called point to point
programming. If a change of half inch smaller diameter is required of the machine from where
it is currently sitting U- .5000 is put in the code. If a grooving tool is making a groove that is
located ¾” behind a groove that is already finished, W-.7500 is input. The letters U&W
represent INCREMENTAL POSTIONING
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Figure 7.16 The Cartesian Coordinate System 2
Table 7.2 The Cartesian Coordinate System 2
P
Absolute
Incremental
X
Z
U
W
1
-5
0
-5
0
2
-4
-4
1
-4
3
-2
-5
2
-1
4
4
5
6
10
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Machining Cycle for Lathe
a. G70 FINISHING CYCLE
Example 1:
Figure 7. 17 Sketch example 1
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O00005 (Finishing Cycle)
T101;
G97 S1000 M03;
G00 G54 X40. Z2.;
G70 P1 Q2 U0.1 W0.1 D0.2 F0.15;
N1 G00 X10;
G01 Z-5;
G03 X20. Z-20. R10.;
G01 Z-20.;
X25. Z-25;
Z-30.;
G02 X35. Z-40. R5.;
G01 Z-45.;
N2 G01 X40,;
G28 U0;
M05;
M30;
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Example 2:
Figure 7. 18 Sketch example 2
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O00002 (ID TURNING);
T101;
G97 S1000 M03;
G00 G54 X0. Z2.;
G70 P3 Q4 U0.1 W0.1 D0.2 F0.15;
N3 G00 X40.;
G01 Z-5.;
X25. Z-10.;
Z-15.;
G03 X20. Z-20. R5.;
G01 Z-25.;
N4 G01 X0.;
G28 U0;
M05;
M30;
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b. G71 O.D./I.D. STOCK REMOVAL CYCLE
Example :
Figure 7. 19 Sketch example 1
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O00001 (OD TURNING)
T101;
G97 S1000 M03;
G00 G54 X40. Z2.;
G71 P1 Q2 U0.1 W0.2 D0.2 F0.15;
N1 G00 X10.;
G01 Z-15.;
X20. Z-25.;
Z-33.;
X35.;
Z-48.;
N2 G01 X40.;
G28 U0;
M05;
M30;
c. G75 O.D./I.D. Grooving Cycle, Peck Drilling
Figure 7. 20 G75 O.D/I.D Grooving cycle, peck drilling
The G75 canned cycle can be used for grooving an outside diameter with a chip break.
With this canned cycle, either a single pecking cycle can be executed (as for a single
groove), or a series of pecking cycles can be performed (as for multiple grooves).
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(G75 X..Z..I..K..F..)





X = Axis Absolute Grooving Depth, Diameter Value (mm)
Z = Axis Absolute Location to The Furthest Peck (mm)
I* = X- Axis Pecking Depth Increment, Radius Value (mm)
K*= Z- Axis Shift Increment Between Pecking Cycles (mm)
F = Feed Rate (mm/rev)
Example :
Figure 7. 21 Sketch example 3
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O00007 (OD GROOVING);
T101;
G97 S500 M03;
G00 G54 X30. Z-20.;
G75 X20. Z-12. I0.2 K1.5 F0.15
G28 U0;
M05;
M30;
Figure 7. 22 Sketch example 4
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O00008 (ID GROOVING);
T101;
G97 S500 M03;
G00 G54 X38.;
Z-20.;
G75 X44. Z-12. I0.2 K1.5 F0.15;
G28 U0;
M05;
M30;
d. G81 DRILL CANNED CYCLE
Figure 7. 23 G81 Drill canned cycle



Z = Absolute Z-Depth (Feeding to Z-Depth from R- Plane) (mm)
R =Rapid to R- Plane (Where Your Rapid, to start feeding) (mm)
F = Feed Rate (mm/rev)
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Example :
Figure 7. 24 Sketch example 5
O000013 (DRILLING);
T101;
G97 S500 M03;
G00 G54 X0. Z10.;
G81 Z-20. R2. F0.05;
G28 U0;
M05;
M30;
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Labwork
Study Case 1
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In this case, we use tool number 1, with spindle speed 1000 rpm. The finishing allowance of
x-axis and z-axis in this process is 0.1 and 0.2, and the depth of cut is 0.2, while the feed rate
is 0.15 mm/rev. ( The initial position cutting tool is X = 40 mm, Z = 2 mm)
O00--- (OD TURNING) Roughing Cycle
T101;
G97 S1000 M03;
G00 G54 X40. Z2.;
G71 P1 Q2 U0.1 W0.2 D0.2 F0.15;
N1 G00 X10.;
G01 Z-15.;
X35. Z-25.;
Z-33.;
X35.;
Z-48.;
N2 G01 X40.;
G28 U0;
M05;
M30;
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Study Case 2
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In this case, we use tool number 1, with spindle speed 500 rpm. The finishing allowance of xaxis and z-axis in this process is 0.15 and 0.21, and the depth of cut is 0.3, while the feed rate
is 0.13 mm/rev. ( The initial position cutting tool is X = 45 mm, Z = 2 mm)
O00--- (OD TURNING) Finishing Cycle
T101;
G97 ____ M03;
G00 G54 ___ ___;
G70 P3 Q4 U0.15 W0.21 D0.3 F0.13;
N3 G00 ___;
___ ___;
G02 ___ ___ R10.;
___ ___;
G03 ___ ___ R10.;
___ ___.;
___.;
N4 G01 X45.;
G28 U0;
M05;
M30;
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Study Case 3
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In this case, we use tool number 1, with spindle speed 1050 rpm. The finishing allowance of
x-axis and z-axis in this process is 0.1 and 0.2, and the depth of cut is 0.1, while the feed rate
is 0.2 mm/rev. ( The initial position cutting tool is X = 60 mm, Z = 2 mm)
O00--- (OD TURNING) Roughing and Finishing Cycle
T101;
G97 ____ M03;
G00 G54 ___ ___;
G71 P1 Q2 ___ ___ ___ ___;
G70 P1 Q2 F0.2;
N1 ___ ___;
___ ___;
___ ___ ___ ___;
___ ___;
___ ___;
___ ___ ___ ___;
___ ___;
___;
N2 G01 X60.;
___ ___ ;
___;
___;
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8th MODULE
MACH3 CNC ROUTER ENGRAVER UNIT CONTROLLER
Objective
1. Students are able and understand about MACH3 CNC controller software
2. Students are able to operate programs that have been made to the CNC Router Engraver
3. Students are able and understand how to operate CNC Router Engraver using MACH3
CNC controller software
4. Students are able and understand how to calibrate CNC Router Engraver using MACH3
CNC controller software
Tools
1. Artsoft MACH3
2. CNC Router Engraver
3. Vernier Calipers
4. Stock
5. Glove
6. Fixture
Basic Theory
Component of CNC
The main components of a CNC system are :
a. Computer Aided Design/Computer Aided Manufacturing (CAD/CAM) program. The part
designer uses the CAD/CAM program to generate an output file called a part program. The
part program, often written in “G-Code” describes the machine steps required to make the
desired part. You can also create a G-Code program manually.
b. A file transfer medium such as a USB flash drive, floppy disk, or network link, transfers
the output of the CAD/CAM program to a Machine Controller.
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c. A Machine Controller. The Machine Controller reads and interprets the part program to
control the tool which will cut the workpiece. Mach3, running on a PC, performs the
Machine Controller function and send signals to the Drives.
d. The Drives. The signals from the Machine Controller are amplified by the Drives so they
are powerful enough and suitably timed to operate the motors driving the machine tool
axes.
e. The machine tool. The axes of the machine are moved by screws, racks or belts which are
powered by servo motors or stepper motors
Figure 8.1 Main parts of CNC system
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Artsoft Mach3
Software
Figure 8.2 Artsoft MACH3
Mach3 is a software developed by Artsoft to user to interpret/define the product part that has
been translated into a G-Code that can be done using CNC production process.
Mach3 is a very flexible program designed to control machines such as milling machines, lathes,
plasma cutters, and routers.
Features of these machines that are used by Mach3 include:

Some user controls. An emergency stop (EStop) button must be provided on every
machine.

Two or three axis of motion, which are usually at right angles to each other (referred to as
X, Y, and Z).

A tool which moves relative to a workpiece. The origin of the reference axes is fixed in
relation to the workpiece. The relative movement can be by (1) the tool moving (e.g. the
quill of a milling spindle moves the tool in the Z direction, or a lathe tool mounted on a
cross-slide and a saddle moves the tool in the X and Z directions) or by (2) the table and
workpiece moving (e.g. on a knee type mill the table moves in the X, Y, and Z directions
while the tool remains fixed in the spindle).
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a. MACH3 Program Run
Figure 8.3 MACH3 Program Run
Mach3 Program Run Interface allow the users to do the main set up for the CNC machine,
which in our case is the CNC Router Engraver, such as:
a) Register zero point for your designed part
b) Insert G-Code from designed part
c) Display the G-Code of your part
d) Run G-Code that have been inserted
Specifically the Program Run Interface can be defined as below:
a) Display G-Code from part
b) Customize the G-Code program in accordance with the requirements
c) Menu to run inserted G-Code
d) Code directory that have been inserted
e) DRO (Digital Readouts). Numbers listed on the menu will indicate the position of
the X, Y, Z, A, B, C in accordance with program requirements.
f) Toolpath Display, picture / simulation is given when G-Code is executed
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g) A menu that provides information about the tools used, the speed of rotation. In
addition the user can also adjust the specification tool that is used through this
menu.
b. Manual Data Input (MDI)
Figure 8.4 MACH3 MDI
This Menu is used to review whether the assigned G-Code is moving the machine to the
designated place or not. The main function is to control the inserted G-code one by one.
c. Toolpath
Figure 8.5 MACH3 Toolpath
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When the program is executed, it shows the tools movement path.
d. Offsets
Figure 8.6 MACH3 Offsets
This menu is used to set the adjustments that will be processed by the CNC machine in
accordance to the shape of the desired product.
e. Settings
Figure 8.7 MACH3 Settings
Used to manually set the calibration of CNC machine.
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f. Diagnostics
Figure 8.8 MACH3 Diagnostics
Is a menu that the function shows the position of the machine at the time of the operation,
it is similar to the toolpath display menu but have different display and different interface
indicators.
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g. MPG (Manual Pulse Generator)
Figure 8.9 MACH3 Settings
To open the MPG menu we can press the "tab" button on our keyboard. MPG is one form
of controls, to control the CNC machine manually. You do this by pressing the arrow keys
on the keyboard or by clicking the buttons X- X+ Y+ Z- Y- Z+ as you needed.
CNC Router Engraver
CNC is a machine controlled by a computer using a numerical language (some code that use
numbers and letters in order to give movement command) as the inputs for the operation
process.
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With CNC Router Engraver only can do milling operation. CNC Router Engraver is included
in the CNC milling machine. CNC milling machine use the axis system of the basic Cartesian
coordinate system. The working principle of CNC milling machine is the table are moving
transversely and horizontally, while the blade / chisel rotates.
The axis symbol for the axis motion direction of the machine are given as follows:
a. X axis for the horizontal direction of motion.
b. Y axis for the transversal direction of motion.
c. Z axis for the vertical direction of motion.
Figure 8.10 CNC Router Engraver
Figure 8.11 Fixture
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Figure 8.10 displayed the whole part of CNC Router Engraver, which will be controlled by
MACH3. The CNC Router Engraver has the capability of executing 2.5 axis and 3 axis
operation.
Figure 8.11 is fixture, To lock the workpiece in the work table so that the workpiece isn’t
thrown during the machining process
CNC Router Engraver, as mentioned in Figure 8.10 has 7 main part with it’s specified
function, which is:
a. CNC Control Box
It had on/off button which functioned as the power supply for the CNC Router
Engraver. It also had E-Stop in case some emergency occur during the machine’s
execution.
b. Spindle
Place where you put your drill / chisel to be used for the part engraving on the work
piece.
c. Working Table
Place for holding up your part stock. The stock is tighten using a clamp to hold still
during the process..
d. X Axis Stepping Motor
Is the motor driving the direction of the X axis (vertical direction) forward and
backward
e. Y Axis Stepping Motor
Is the motor driving the direction of the Y axis (vertical direction) forward and
backward
f. Z Axis Stepping Motor
Is the motor driving the direction of the Z axis (vertical direction) forward and
backward
g. Cable Chain
As a place for the movement of the cable - the cable each axis stepper motors on the
CNC machine
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h. Fixture
To lock the workpiece in the work table so that the workpiece isn’t thrown during the
machining process
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9th MODULE
ASSEMBLY, FINISHING AND MOLDING
Objective
1. Students know and understand the concept of Assembly.
2. Students understand the assembly process and method used in the manufacturing process.
3. Students know and understand type of joints that is used in the manufacturing process.
4. Students know and understand type of finishing process that is used in the manufacturing
process.
5. Students know and understand type of molding process that is used in the manufacturing
process
Tools
1. Stock that has been created in the previous process.
2. Screw driver
3. Sandpaper
4. Markers
5. Ruler / Calipers
6. 4 Hingers (Engsel)
7. 8 Screw Joints
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Basic Theory
Assembly
Assembly is a process of drafting and unification of some component parts into an instrument
or machine that has a particular function. The work of the assembly started when an object is
ready to install, and ended when the object was have fused perfectly.
a. Types of Assembly
There are several types of commonly used assembly in industry. Usually a factor of form
and amount of products that would yield of decisive importance. In general there are two
types of assembly:
 Manual Assembly
The assembly process worked conventionally or using manpower without using any
supportive tools.
 Automated Assembly
Automated assembly refers to a manner of producing goods by use of automated
machinery or assembly robots and a systematic approach to assembling goods that
operates at least partly independently from human control.
b. Methods of Assembly
1) Cascade Method
Cascade method is a method of assembly between components with a step sequence.
The method is widely used for coupling system between components using the rivet.
2) Balance Method
A method of balance in assembling is process of grafting components by using spot
welding. Assembly with spot welding is widely used for grafting thin plates. The
application process of grafting by spot welding it is commonly used in the auto industry
and trains, as well as aircraft industry.
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3) Knockdown Method
Knockdown method is a widely used in assembly process. The main purpose of
this method is:
1. Facilitate the mobility or transportation
2. For the maintenance or replacement of components in sections.
3. Facilitate in operational work
4. Simplifying product construction
Assembly process with this method generally using bolts and nuts or screws. Assembly
with this method must be done carefully, especially in the case of drilling the holes that
will be assembled
Factor Affecting Assembly
a. Types of Metal
Every materials have its own characteristic, this characteristic will determine which
assembly method is the most suitable to be used in our assembly process. So before we do
an assembly process we must know the type and characteristic of the material that we pick.
b. Strength
Consideration of the power required for a construction, should have been counted when
planning what will be explained, in this case by considering what the construction is used.
On this basis we can choose the connection method in the basic assembly process for the
construction of the power connection required.
c. Selection of Joining Method
Selection of joining methods are closely related to the type of materials and the power
connection required because each method of connection has its own privileges.
d. Strengthening Method Selection
The strengthening of plates aims to give rigidity on the plate subjected to the process of
formation. Because the plate material is relatively thin, the plate is usually required
reinforcement at both the edge and the body.
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e. Tolerance
Tolerance in assembly envisaged under pair between an element are assembled into bigger
components.
f. Form / Display
The appearance of a product intensely affecting against the value of selling the product
itself. The appearance really prompted by a picture or design. A display adapted to use of
construction in the field.
g. Ergonomic
Ergonomic is defined in this assembly is a match between the products with the
convenience of the user (end user). This means that if the product used does not cause
fatigue, dangerous, boring, etc
h. Finishing
Finishing or the final work is really an important part in the process of assembly. Finishing
this will give the final appearance of an object to the sale value.
Joint
According to Darma Adjie (2012) joint function is to fasten a machinery construction, whether
permanent or not. There are two kinds of joint in general:
a. Semi Permanent Joint
A temporary joint, so it still can be disassembled while still in normal condition.

Riveted Joint
Riveted joints are being replaced by the more economical welded and glued joints.
Until the appearance of welding, riveting was the main joining method used in the
construction of metal bridges and hoisting cranes (stress-relieved or strong joints),
boilers (tight stress-relieved or tight strong joints), and low-pressure tanks (tight
joints). Riveted joints are used for parts made of materials that cannot be welded or
heated, such as thin-walled parts (made of sheet material) in aircraft construction
and in the manufacture of bus and trolleybus bodies, as well as for heavily loaded
joints subject to impact and vibratory loads under operating conditions. Riveted
joint can be used to:
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a) As the strength joint in light metal construction (multilevel construction,
bridges construction and aircraft construction)
b) As an impermeable joint for water tank, chimney plates, and pipes
c) As a joint nails for aircraft and vehicle construction
Figure 9. 1 Riveted join on global spec

Bolt Joint
The bolt joint is one of the non-permanent joint. This connection can be assembled
or disassembled according to the desired state. In machinery construction the bolt
itself divided by it’s function :
1) Translucent Bolt
Translucent bolt used to tie the two elements or parts through the hole to
penetrate.
2) Tap Bolt
These bolts are used to clamp two parts of the machine elements.
3) Stud Bolt
This bolt does not have a head, but there are screw on each side.

Screw Joint
A screw joint is a special type of sleeve joint that enables screws to be tightened
into surrounding joint sleeves. These are often used for metal rod assembly or
corners that require a threaded screw for structural stability.
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Figure 9. 2 Screw Joint

Bolt
In general, hexagon-shaped nut. However, for the use of a variety of shapes made
various nut head, including:
a. Hex
b. Heavy Hex
c. Nylon Insert Lock
d. Jam
e. Nylon Insert Jam Lock
f. Wing
g. Cap
h. Acorn
i. Flange
j. Tee
k. Square
l. Prefailing Torque Lock
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Figure 9. 3 Bolt
b. Permanent Joint
Is a fixed joint, so they could not detachable forever, except by ruining it first.
•
Weld Joint
Welding is a process of grafting of metal being one due to heat with or without the
influence of pressure or can also be defined as a bond metallurgy inflicted by the force
of attraction draws between the atoms.
There are 2 types of welding:
1) Caribide welding / Autogenus welding
A welding that uses a propellant of oxygen gas (acid) and acetylene gas (acetylene).
In steel construction, this welding is used for light work or secondary construction
such as metal fences, trellises, and so on.
2) Electric Welding
Electric welding is the process of heating and welding two pieces of metal together
using a powerful electric current. It was invented by prof. Elihu Thomson. It
requires the use of a specialized device called a dynamo that releases the current
used for welding.
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Finishing
Finishing processes required for the objects or components to obtained maximum precision
object size. Some finishing process that is often performed are grinding, sanding process, and
varnish.
Finishing processes has to be done for the purpose of cleaning, removal the unwanted parts and
protect the desired parts to make it more interesting. And the cleaning process is done to remove
impurities such as dust, oil or crust which is resulted from machining process.
The finishing process itself can be done after or before the assembly process, depending on the
shape of the part being processed, whether it can be assembled (knock down) or not. If the part
can be apart pairs in the finishing process is usually done first prior to the assembly process.
However, if parts can not be assembled the assembly process will be done first and followed by
the finishing process.
Kinds of finishing:
1. Grinding Process
Grinding machine is a equipment used for the installation of the grinding wheel, to
remove the surface of the workpiece.
Types of Grinding Process:
a. Angle Grinder
Grinding wheel used in Angle Grinder is a thin grinding disc. Angle Grinder can
be used to scrape the surface of the workpiece (grinding) and cut the workpiece.
Angle Grinder is usually used for smoothing the surface of the workpiece after
welding process, especially in large-sized workpieces.
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Figure 9. 4 Angel Grinder
b. Bench Grinder
Similar to Angle Grinder, grinding machine position just attached to the holder. To
perform grinding, the workpiece is approximated and affixed to the rotating
grinding wheel to the workpiece surface is eroded by the grinding wheel. Grinding
wheel used in Bench Grinder is thicker than the size of the grinding wheel in Angle
Grinder. Bench Grinder is widely used for sharpening a chisel, scrape and smooth
the surface of the workpiece after the workpiece welding process.
Figure 9. 5 Bench Grinder
c. Drop Saw
Drop Saw is a grinding machine to cut the material of the workpiece plate or pipe.
Grinding wheel used is a thin grinding disc that is played at high speed. Drop Saw
can cut the workpiece cutting plates or pipes of steel materials quickly.
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Figure 9. 6 Drop Saw
2. Sanding Process
Sanding process is one important step in the woodworking process. To produce a wood
product with good quality, it is necessary to have flat and smooth surface which is only
achieved with the sanding process. The quality of finishing is largely determined by the
quality of the sander required.
Type of Sander:
a. Hand Sander
Hand sander is hand sanding machine. This tool is more accurately described as a
small tool or machine. This tool must be moved manually by hand and still need to
employ skilled operators to be able to get a good sanding results. Nonetheless
sanding machine has been very helpful in doing sanding the wood. This sanding
machine can do the job to sanding the wood surface with a faster , more consistent
with the use of human labor that much smaller. Hand sander is available in various
sizes and shapes that can be selected according to the shape and size of the material
are sanded.
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Figure 9. 7 Hand Sander
b. Wide Belt Sander
Wide belt sander is a sanding machine for a wide surface. Wide belt sander is a
machine that uses a belt sanding sandpaper. This tool has a set of abrasive belt
contact with a roll to do the sanding. This machine could have some sandpaper belt
to do some sanding process at once. There are also machines that have double head
that could work to do sanding on both sides of the panel surface at once. Workpiece
in the form of flat panels inserted into the machine by using a feeding conveyor to
undergo a series of processes in the sanding machine.
This machine is most appropriate tool to perform calibration on the surface of the
big panels. If we require the panels with the same thickness then we need a wide
belt sander machine with good quality. Wood panels put into this tool and came out
with the same thickness in each side. Wide belt sander with good quality is needed
in the modern woodworking industry that makes products with the size of the panels
of the same thickness with high precision .
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Figure 9. 8 Wide Belt Sander
c. Stroke Sander
Stroke sander sanding machine is a tool that has a long sanding belt. A long sanding
belt rotates to make the process of sanding the surface. These machines still require
the operator to perform sanding with sandpaper belts by pressing the surface to be
sanded.
This machine can produce the sanding surface with excellent quality. The operator
can do the setting and control of the sanding process with a set time and sandpaper
belt presses. Stroke is also relatively flexible to do the sanding process on a slightly
uneven surface. These machines are more widely used to do the final sanding on
wood panels before entering the finishing process.
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Figure 9. 9 Stroke Sander
d. Brush Sander
This sanding machine is not using sandpaper belt as a tool to do the sanding.
Instead, this tool uses a brush consists of fabric that is cut thin sandpaper and a
buffer as a tool to do the sanding.
Brush sander sanding machine that is designed to make the process of sanding
work on objects that are not flat. Sanding with a brush sander will not be able to
produce a flat surface and smooth like other ampals tool but is enough to cut and
reduce feathering existing wood on the wood surface.
Figure 9. 10 Brush Sander
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3. Polishing Process
Polishing is a finishing process that is generally performed on a wooden stock that serves
as a coating to the color of the wood stock. Polish process is done on the outer portion of
stock directly exposed to the sun.
4. Painting by using Spray Gun
Spray gun is a tool used in the finishing process to give color to the stock. The workings
of the spray gun in general is, by inserting dye into the tube of paint, and spray it on the
stock by utilizing the thrust of air (usually coming from the compressor).
Shape Spray Gun:
a) HVLP (High Volume Low Pressure): the position of the tube is under the gun most
widely used for applications that require a base coat as much as the amount of
material covering the wood pores.
Figure 9. 11 High Volume Low Pressure
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b) Gravity Spray Gun: Tube located on top of the spray gun and it is usually used for
final finishing (top coat) with a higher viscosity.
Figure 9. 12 Gravity Spray Gun
c) Airless Spray Gun tube connected directly to the large (20 liters) of finishing
materials and instantly have two channels at the base. This type is usually used for
staining in bulk material mixing color finishes that are not too large deviations.
Figure 9. 13 Airless Spray Gun
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Molding
Molding is the process of manufacturing by shaping liquid or flexible raw material using a rigid
frame called a mold or matrix. This may have been made using a pattern or model of the final
object.
A mold or mould is a hollowed-out block that is filled with a liquid or flexible material like
plastic, glass, metal, or ceramic raw materials. The liquid hardens or sets inside the mold, are
adopting its shape. A mold is the counterpart to a cast. The very common bi-valve molding
process uses two molds, one for each half of the object. Piece-molding uses a number of
different molds, each creating a section of a complicated object. This is generally only used for
larger and more valuable objects.
a. Injection Molding
Injection molding is a thermoplastic material processing method in which the molten
material for heating injected by the plunger into a mold which is cooled by the water where
the material will be cool and harden so it can be removed from the mold. This is the
molding process:
Figure 9. 14 Injection Molding
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Sequence in a simple injection molding process is as follows:
1. Door closing. Injection process begins when the safety door is closed
2. Mold clamping. Moveable platen moves forward so that the mold is closed and
locked.
3. Injection. Injecting molten resin into the mold has
4. Holding
Maintain the shape of the resin that has been injected with a pressure which is then
called holding pressure
5. Cooling
The process of cooling the resin in the mold that has been injected to harden and form
unchanged
6. Charging / Recovery / Dosing
At the time of the cooling process, the resin that has been previously in the drying
hopper then scaled through the feeding hopper and in shatters through the round screw
in the injection unit and ready for the next injection process
7. Mold open
Moveable platen moves backward / open mold after the injection process is
completed
8. Eject
b. Blow Molding
Blow molding is a manufacturing process by which hollow plastic parts are formed. In
general, there are three main types of blow molding: extrusion blow molding, injection
blow molding, and injection stretch blow molding. The blow molding process begins with
melting down the plastic and forming it into a parison or in the case of injection and
injection stretch blow molding (ISB) a preform. The parison is a tube-like piece of plastic
with a hole in one end through which compressed air can pass.
The parison is then clamped into a mold and air is blown into it. The air pressure then
pushes the plastic out to match the mold. Once the plastic has cooled and hardened the
mold opens up and the part is ejected. There are several different types of blow molding.
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c. Injection Blow molding
Injection blow molding is used in the production of large quantities of hollow plastic
objects.
Figure 9. 15 Injection Blow Molding
d. Extrusion Blow Molding
In extrusion blow molding (EBM), plastic is melted and extruded into a hollow tube (a
parison). This parison is then captured by closing it into a cooled metal mold. Air is then
blown into the parison, inflating it into the shape of the hollow bottle, container, or part.
After the plastic has cooled sufficiently, the mold is opened and the part is ejected.
Figure 9. 16 Extrusion Blow Molding
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e. Stretch Blow Molding
The main applications of stretch blow molding includes jars, bottles, and similar containers
because it produces items of excellent visual and dimensional quality compared to
extrusion blow molding. The process first requires the plastic to be injection molded into a
'preform' with the finished necks (threads) of the bottles on one end.
Figure 9. 17 Stretch Blow Molding
Labwork
1. Prepare a stock that has been created in the previous module
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2. Prepare the tools used ( Hinges (Engsel), Drill, Sandpaper, Screwdriver, )
3. Measure stock (frame cover) using a ruler/calipers to determine the dimensions that will be
embed the hinges and marked it, with dimensions as follows (1,5cm x 0,8cm ).
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4. Make holes for the joint on the hinges in accordance with the position of the hinges in stock,
after that hinges can be interconnected with stock. On the other hinges part do the same on
the press stock so that molding stock and press stock can be interconnected.
5. To refined the stock, finishing process will be performed by using a sandpaper.
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