Exp no :1

Date:

Bolt (thread) making on Lathe machine

AIM:
To prepare a bolt on lathe machine
TOOLS REQUIRED:
Lathe Machine, Single Point Cutting Tool, Work piece, Surface gauge, surface plate, V-Block, Centre
Punch, Tool kit.

PROCEDURE:

Bolt making on a lathe machine involves turning a rod or blank into a threaded bolt by cutting external
threads on its surface. Here's a step-by-step guide on how to make a bolt on a lathe machine:

Step 1:

Select the Material Choose a suitable material for the bolt, such as steel or stainless steel. Ensure that
the diameter of the material is slightly larger than the desired diameter of the finished bolt.

Step 2:

Mount the Material on the Lathe Securely mount the material between the lathe centers. Use the chuck
and tailstock to hold the material firmly in place. Make sure it is centered and aligned properly.

Step 3:

Facing the End If the end of the material is rough or uneven, start by facing it. Use a facing tool to create
a flat and smooth surface at the end of the material. This step ensures that the threads start from a clean
and perpendicular surface.

Step 4:

Calculate Thread Dimensions Determine the thread pitch, major diameter, and minor diameter for the
bolt. The thread pitch is the distance between adjacent thread crests, and the major diameter is the largest
diameter of the thread. The minor diameter is the smallest diameter of the thread.

Step 5:

Choose the Correct Tooling Select the appropriate cutting tool for threading. You can use single-point
threading tools or threading inserts depending on your lathe and preferences.
Step 6:

Set the Lathe Speed and Feed Rate Set the lathe to an appropriate speed and feed rate for cutting the
threads. Refer to the material and tooling guidelines for recommended cutting speeds and feeds.

Step 7:

Start Threading Engage the threading tool with the material and begin cutting the threads. Move the tool
along the length of the material while simultaneously rotating the material to create the desired thread
profile. Make sure to engage the half-nut or threading lever to synchronize the lathe spindle with the
lead screw.

Step 8:

Check Thread Dimensions Periodically check the thread dimensions using thread gauges or micrometres
to ensure they meet the required specifications.

Step 9:

Thread to Desired Length Continue threading the bolt until you reach the desired length. Use a thread
stop or thread dial indicator to control the threading process accurately.

Step 10:

Chamfer the End (Optional) Chamfer the end of the bolt slightly to remove any sharp edges and improve
the appearance.

Step 11:

Cut Off the Bolt Once the threading is complete, cut off the bolt from the material using a parting tool
or a cutoff tool.

Step 12:

Check the Threads Inspect the threads on the bolt to ensure they are clean, accurate, and meet the required
specifications.

RESULT
The bolt is manufactured on lathe machine.
Exp no :2
Date:

Gear cutting on a Milling machine

AIM:
To perform spur gear cutting using milling machine on a work piece.
INTRODUCTION:
Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or disk with the
teeth projecting radially, and although they are not straight-sided in form (they are usually of special
form to achieve constant drive ratio, mainly involute), the edge of each tooth is straight and aligned
parallel to the axis of rotation. These gears can be meshed together correctly only if they are fitted to
parallel shafts.

MATERIAL USED
Cast iron blank
TOOLS REQUIRED
1. Vertical Milling machine
2. vernier caliper
3. Holding Materials
4. Milling Tools
5. Mandrel
Module: 1.5
Cutter no:4
Number of teeth : 30
Simple indexing
PROCEDURE:
Gear cutting on a milling machine involves the process of milling gear teeth onto a gear blank or a
workpiece to create a functioning gear. Milling machines are capable of cutting both spur gears (parallel
to the axis of rotation) and helical gears (at an angle to the axis of rotation). The process typically
involves using a rotary cutter called a gear cutter or a hob to remove material and form the gear teeth.
Here's a general guide on how to cut spur gears on a milling machine:

Step 1:

Gear Design and Calculation Determine the gear specifications, such as the number of teeth, the module
(or pitch), and the gear's outside diameter. Use gear design software or gear reference tables to calculate
the dimensions accurately.

Step 2:

Gear Blank Preparation Obtain a gear blank made of the desired material and ensure it has been turned
to the correct diameter and thickness. The blank's diameter should match the gear's outside diameter, and
it should have a center hole for mounting on the milling machine arbor.

Step 3:

Mounting the Gear Blank Securely mount the gear blank on the milling machine using a suitable arbor
or fixture. Ensure the gear blank is centered and aligned properly to avoid any errors during the cutting
process.

Step 4:

Choosing the Cutter Select the appropriate gear cutter for the desired gear specifications. Gear cutters
are available in various forms, such as single-tooth cutters for spur gears or multi-tooth hobs for helical
gears.

Step 5:

Set the Milling Machine Set up the milling machine for gear cutting. Adjust the machine's speed, feed
rate, and depth of cut based on the material and cutter being used. Refer to gear cutting reference tables
or gear cutting software for the recommended settings.

Step 6:
Cutting Gear Teeth Start the milling machine and engage the gear cutter with the gear blank. Move the
milling table or the gear blank to start cutting the gear teeth. The cutter will generate the gear tooth
profile as it rotates.

Step 7:

Indexing For spur gears, you'll need to index the gear blank after each tooth is cut to move to the next
position. This ensures accurate spacing between the teeth.

Step 8:

Repeat the Process Continue the cutting process until all the gear teeth are completed.

Step 9:

Deburring and Finishing After cutting all the gear teeth, carefully remove the gear blank from the milling
machine. Deburr the gear teeth and inspect the gear for any defects or errors.

RESULT:
The given work piece as is subjected to gear generating operation to become a finished work piece
Exp no :3
Date:

Machining a block on Shaper machine

AIM
To produce a rectangular on a rectangular blank with the help of shaping operations
TOOLS REQUIRED
1. Shaper machine,
2. spirit level gauge,
3. shaper tools,
4. surface plate,
5. vernier height gauge,
6. scriber,
7. vernier caliper

PROCEDURE:
Machining a block on a shaper machine involves the process of shaping a workpiece into a desired shape
and size using a single-point cutting tool. The shaper machine is a type of machine tool used for linear
or flat surface machining. It utilizes a reciprocating motion of the cutting tool to remove material from
the workpiece. Here's a step-by-step guide on how to machine a block on a shaper machine:
Step 1:

Select the Workpiece Material and Block Choose the appropriate material for the workpiece, considering
factors such as hardness, machinability, and application requirements. The workpiece should be a block
with the initial dimensions slightly larger than the final desired dimensions.

Step 2:

Secure the Workpiece Fix the workpiece securely on the shaper machine table using clamps or fixtures.
Ensure that the workpiece is stable and firmly held to avoid movement during the machining process.

Step 3:

Select the Cutting Tool Choose a suitable cutting tool for the machining operation. The cutting tool
should have the appropriate geometry, size, and material for cutting the workpiece material effectively.

Step 4:

Set the Tool Height and Position Adjust the tool height and position relative to the workpiece surface.
The cutting tool should be properly aligned and set to the desired depth of cut.

Step 5:

Set the Shaper Machine Speed and Feed Rate Adjust the shaper machine's speed and feed rate based on
the workpiece material and the cutting tool being used. Consult cutting speed and feed rate reference
tables or machining handbooks for recommended values

Step 6:

Start the Shaper Machine Start the shaper machine and engage the cutting tool with the workpiece. The
shaper machine will move the cutting tool in a reciprocating motion along the workpiece surface,
removing material in each pass.

Step 7:

Feed the Workpiece Control the feed mechanism to move the workpiece in the direction perpendicular
to the cutting stroke. The feed rate determines the rate at which material is removed from the workpiece.

Step 8:

Continue Machining Passes Continue the machining process, making multiple passes with incremental
depths of cut until the desired shape and size of the block are achieved.
Step 9: Check Dimensions and Tolerances Regularly check the dimensions and tolerances of the
machined block using measuring instruments like calipers, micrometers, or height gauges. Ensure that
the final dimensions meet the required specifications.

Step 10: Finish and Deburr After achieving the desired shape and size, finish the surface of the machined
block to obtain a smooth and even surface. Remove any burrs or sharp edges using appropriate deburring
tools.

Step 11: Clean Up Clean the work area and the shaper machine after completing the machining process.
Remove any chips or debris generated during machining.

RESULT

The required model is obtained and its dimensional accuracy is verified

Exp no :4
Date:

Drilling holes on Drilling machine

AIM

To perform drilling operations on the given M.S Flat work piece.

APPARATUS
1. Drilling Machine with standard accessories
2. Work piece
MATERIAL
Mild Steel flat plate 50 mm × 50 mm ×10 mm

PROCEDURE:
Drilling holes on a drilling machine is a fundamental machining operation used to create precise holes
in various materials. Here's a step-by-step guide on how to drill holes using a drilling machine:

Step 1:

Select the Workpiece and Drill Bit Choose the appropriate workpiece material and select a drill bit
suitable for the material and the hole size needed. The drill bit should have the correct diameter and be
designed for drilling in the specific material (e.g., wood, metal, plastic).

Step 2:
Secure the Workpiece Place the workpiece on the drilling machine table or workbench and secure it
using clamps or a vise. Make sure the workpiece is stable and firmly held to prevent any movement
during drilling.

Step 3:

Set the Drill Speed and Feed Rate Adjust the drilling machine's speed and feed rate based on the
workpiece material and the diameter of the drill bit. Slower speeds are typically used for drilling in
harder materials, while faster speeds can be used for softer materials. Consult the drilling machine's
manual or reference tables for recommended speed and feed rate values.

Step 4:

Align the Drill Bit Position the drill bit above the desired drilling location on the workpiece. Use the
drilling machine's adjustments to align the drill bit accurately with the marked or center-punched spot.

Step 5:

Lower the Drill Bit Lower the drill bit slowly onto the workpiece surface. Apply moderate pressure to
keep the drill bit engaged with the workpiece while starting the drilling operation.

Step 6:

Start Drilling Activate the drilling machine and start the drilling operation. Apply a steady and even
downward force to maintain a consistent feed rate. Allow the drill bit to cut through the workpiece
gradually.

Step 7:

Use Coolant (If Required) For certain materials, such as metals, using cutting fluid or coolant can help
dissipate heat and prolong the life of the drill bit. If required, apply a small amount of coolant to the
drilling area.

Step 8:

Clear Chips During drilling, periodically retract the drill bit to clear away the chips and debris from the
hole. This helps maintain efficient cutting and prevents chip clogging.

Step 9:

Drill to the Desired Depth Continue drilling until you reach the desired hole depth. Use a depth stop or
gauge to ensure consistent hole depth across multiple workpieces.
Step 10:

Finish and Deburr After drilling, remove the workpiece from the drilling machine. If necessary, deburr
the edges of the hole using a deburring tool to remove any sharp edges or burrs.

Step 11:

Clean Up Clean the drilling machine and the work area after completing the drilling process. Remove
any chips or debris from the drilling operation.

RESULT

Drilling operations on the given M.S Flat work piece is completed.

Exp no :5
Date:

Finishing of a surface on Surface-grinding machine

AIM:

To perform plain surface grinding on the given work piece to the required dimensions

APPARATUS REQUIRED:

• Grinding machine

• Grinding Wheel

• Vernier Calliper
MATERIAL REQUIRED:

• MS / CI plate

PROCEDURE:
Surface grinding is a precision machining process used to obtain smooth and flat surfaces on
workpieces. The surface grinding machine uses a rotating grinding wheel to remove material from
the workpiece surface, creating a finished and accurately dimensioned surface. Here's a step-by-step
guide on how to finish a surface on a surface grinding machine:

Step 1:

Select the Workpiece Choose the workpiece material and ensure it is properly prepared and mounted
on the surface grinding machine. The workpiece should have a flat and clean surface to ensure
accurate grinding results.

Step 2:

Choose the Grinding Wheel Select the appropriate grinding wheel for the workpiece material and
surface finish requirements. Different grinding wheels are available for various materials and surface
finish specifications.

Step 3:

Set Up the Surface Grinding Machine Make sure the surface grinding machine is properly set up and
aligned. Check the machine's alignment and levelness to ensure precise and consistent grinding
results.
Step 4:

Adjust the Grinding Wheel Position Adjust the position of the grinding wheel relative to the
workpiece. The grinding wheel should be parallel to the worktable and the workpiece's surface.

Step 5:

Set the Grinding Depth and Feed Rate Set the grinding depth and the feed rate for the grinding
operation. The grinding depth determines how much material is removed from the workpiece surface
during each pass, while the feed rate controls the speed at which the grinding wheel traverses the
workpiece.

Step 6:

Start Grinding Switch on the surface grinding machine and start the grinding process. Slowly lower
the grinding wheel onto the workpiece surface while applying a constant and even pressure.

Step 7:

Traverse the Workpiece Move the workpiece back and forth under the grinding wheel to grind the
entire surface evenly. Use the crossfeed and longitudinal feed controls to achieve the desired surface
finish and remove any irregularities.

Step 8:

Check Surface Flatness and Roughness Periodically check the surface flatness and roughness using a
surface plate or precision measuring instruments. Adjust the grinding depth and feed rate if necessary
to achieve the desired surface quality.

Step 9:

Coolant (If Required) If the grinding process generates significant heat, use coolant or cutting fluid
to cool the workpiece and grinding wheel. Cooling helps prevent workpiece damage and extends the
life of the grinding wheel.

Step 10:

Continue Grinding Passes Repeat the grinding process with multiple passes until the desired surface
finish and dimensional accuracy are achieved.

Step 11:
Finishing Pass For the final finishing pass, reduce the grinding depth and apply a lighter feed rate to
produce a smoother and finer surface finish.

Step 12:

Inspect and Clean Up After completing the surface grinding process, inspect the finished surface for
any defects or imperfections. Clean the workpiece and the surface grinding machine, removing any
grinding debris and coolant.

RESULT:

plain surface grinding is performed on the given work piece up to the required Dimensions.
Exp no :6
Date:

Arc welding experiment

AIM:
To prepare a single V butt joint.
MATERIALS REQUIRED:
Mild steel flat 100 mm X 50 mm X 5 mm.
TOOLS REQUIRED:
Flat rough file, try square, step down transformer, electric lugs, shield, goggles, gloves, electrode
holder, electrode, chipping hammer, wire brush.

PROCEDURE:
1. Safety Precautions:
• Wear appropriate personal protective equipment (PPE), including welding gloves,
a welding helmet or goggles, and protective clothing.
• Ensure the work area is well-ventilated or use an exhaust system to remove welding
fumes.
• Keep the welding machine and work area dry to avoid electrical hazards.
2. Setup:
• Position the welding machine in a stable location and connect it to a suitable power
source.
• Insert the welding electrode into the electrode holder of the welding machine.
 • Clean the welding surface of the mild steel plates using a wire brush to remove any
rust, paint, or contaminants.
3. Adjust Welding Settings:
• Set the welding machine to the appropriate current and voltage settings based on
the electrode size and material thickness.
• For starters, use a lower current setting for thinner materials and increase it
gradually for thicker materials.
4. Welding Technique:
• Hold the electrode holder firmly and position it at about a 90-degree angle to the
workpiece.
• Strike an arc by lightly tapping the electrode on the workpiece and quickly lifting
it.
• Once the arc is established, maintain a consistent arc length (usually around 1/8
inch or 3-4 mm) throughout the welding process.
• Move the electrode in a steady and controlled manner along the joint, maintaining
a slight weaving motion to ensure proper fusion.
5. Welding Joints:
• Practice different welding joint configurations, such as butt joints, lap joints, and
T-joints.
• Experiment with different welding positions (flat, horizontal, vertical, and
overhead) to gain experience with various welding scenarios.
6. Finish Welds:
• After completing each weld, allow the weld to cool briefly.
• Use a chipping hammer to remove any slag (residue) left on the weld.
• Inspect the welds for quality and consistency.
7. Safety and Clean Up:
• Turn off the welding machine after finishing the experiment.
• Store the welding machine and electrodes properly.
• Clean the work area, removing any welding debris and tools.

RESULT
V- Butt joint has been produced by using arc welding.
Exp no :7
Date:

Tool grinding (to provide tool angles) on tool-grinder machine.

AIM:

To grind the single point cutting tool as per dimensions

APPARATUS REQUIRED:

• Tool grinding cutter

• Profile projector
• Ms square

PROCEDURE:

Step 1:

Select the Cutting Tool Choose the cutting tool that needs to be ground. Common cutting tools include
end mills, drills, lathe tools, and inserts for indexable tools.

Step 2:

Set Up the Tool Grinder Machine Ensure the tool grinder machine is properly set up and aligned. Check
that the grinding wheel is in good condition and properly mounted on the grinder.

Step 3:

Dress the Grinding Wheel (if required) If the grinding wheel has become dull or has an uneven surface,
dress the wheel using a dressing tool to restore its cutting ability and shape.

Step 4:

Adjust the Tool Grinder Settings Adjust the tool grinder settings based on the type and size of the cutting
tool you are grinding. Set the appropriate angles, wheel speed, and feed rate for the specific tool.

Step 5:

Mount the Cutting Tool Mount the cutting tool securely in the tool holder or on the worktable of the tool
grinder machine. Make sure the tool is positioned accurately for grinding.

Step 6:
Grinding the Rake Angle Grind the rake angle by moving the tool against the grinding wheel. The rake
angle is the angle between the tool's cutting edge and a reference line perpendicular to the workpiece.

Step 7:

Grinding the Clearance Angle Grind the clearance angle by adjusting the tool's position and the grinding
wheel's angle. The clearance angle is the angle between the tool's cutting edge and the tool's axis.

Step 8:

Grinding the Relief Angle Grind the relief angle by adjusting the tool's position and the grinding wheel's
angle. The relief angle is the angle between the tool's flank (side) and the ground surface.

Step 9:

Check Tool Angles Periodically check the tool angles using appropriate measuring instruments, such as
protractors or specialized tool angle gauges, to ensure they match the required specifications.

Step 10:

Repeat if Necessary If the tool angles are not within the desired tolerances or need further adjustment,
repeat the grinding process until the correct angles are achieved.

Step 11:

Clean Up Clean the tool grinder machine and the work area after completing the grinding process.
Remove any grinding debris and coolant.

RESULT:
The given single point cutting tool as per given specification
Exp no :8
Date:

Soldering & Brazing experiment

AIM:

To create a strong and reliable joint between two metal pieces using soldering and brazing techniques.

MATERIALS NEEDED:

1. Metal pieces or components to be joined (e.g., copper, brass, or steel)

2. Soldering and brazing rods or filler metals (appropriate for the base metal)

3. Flux (appropriate for soldering or brazing process)

4. Soldering iron or torch for soldering

5. Brazing torch or oxy-acetylene torch for brazing

6. Heat-resistant gloves

7. Safety glasses

8. Fireproof surface or work area

PROCEDURE:

Soldering:

1. Clean the Metal Surfaces:

• Ensure the metal surfaces to be soldered are clean and free from any dirt, grease, or oxidation.

• Use sandpaper or a wire brush to clean the surfaces.

2. Apply Flux:

• Apply a thin layer of soldering flux to the cleaned surfaces. Flux helps remove oxidation and
promotes the flow of solder.

3. Position the Components:

• Position the metal components to be joined together, ensuring a tight fit.

4. Heat the Soldering Iron:

 • Heat the soldering iron to the appropriate temperature for the solder and base metal being used.

5. Apply Solder:

• Touch the soldering iron to the joint and let it heat up the metal surfaces.

• Apply the solder to the joint, allowing it to melt and flow between the metal surfaces.

6. Cool and Inspect:

• Allow the joint to cool and solidify.

• Inspect the soldered joint for any defects or weak spots.

Brazing:

1. Clean the Metal Surfaces:

• Ensure the metal surfaces to be brazed are clean and free from any dirt, grease, or oxidation.

• Use sandpaper or a wire brush to clean the surfaces.

2. Apply Flux:

• Apply a thin layer of brazing flux to the cleaned surfaces. Flux helps remove oxidation and promotes
the flow of the brazing filler metal.

3. Position the Components:

• Position the metal components to be brazed together, ensuring a tight fit.

4. Heat the Brazing Torch:

• Light the brazing torch and adjust the flame to the appropriate temperature for the brazing filler
metal and base metal being used.

5. Apply Brazing Filler Metal:

• Heat the joint with the torch until it reaches the appropriate temperature for the brazing filler metal
to melt.

• Apply the brazing filler metal to the joint, allowing it to flow and fill the gap between the metal
surfaces.

6. Cool and Inspect:

• Allow the joint to cool and solidify.

 • Inspect the brazed joint for any defects or weak spots

RESULT:
Exp no :9
Date:

Metal Cutting Experiment

AIM:

To measure Cutting Force and cutting measurement during metal cutting

PROCEDURE:

Metal cutting experiments involve various measurements to understand the cutting process,
optimize machining parameters, and improve tool life. Here are two common metal cutting
experiments

1. Cutting Force Measurement: To measure the cutting forces during a metal cutting
operation. Equipment Needed:

• Dynamometer or force transducer (to measure cutting forces in three directions

- axial, radial, and tangential)

• Metal cutting machine (lathe, milling machine, or machining center)

• Workpiece material (metal specimen)

• Cutting tool (appropriate for the workpiece material) Procedure:

1. Set up the dynamometer or force transducer on the metal cutting machine to measure
the cutting forces.
2. Fix the workpiece material securely on the machine's worktable or chuck.
3. Mount the cutting tool in the tool holder and position it to start the cutting operation.
4. Start the metal cutting machine and begin the cutting process.
5. Collect data from the dynamometer or force transducer throughout the cutting operation
to record the cutting forces.
6. Analyze the data to determine the maximum cutting forces, cutting force components,
and their variation during the machining process.
7. Use the results to optimize cutting parameters, tool selection, and workpiece material
for efficient and safe metal cutting operations

.
 2. Cutting Temperature Measurement: To measure the temperature generated during
metal cutting. Equipment Needed:

• Thermocouples or infrared thermometers

• Metal cutting machine (lathe, milling machine, or machining center)

• Workpiece material (metal specimen)

• Cutting tool (appropriate for the workpiece material) Procedure:

1. Place thermocouples or use infrared thermometers to measure the temperature at specific

points on the workpiece and cutting tool.
2. Fix the workpiece material securely on the machine's worktable or chuck.
3. Mount the cutting tool in the tool holder and position it to start the cutting operation.
4. Start the metal cutting machine and begin the cutting process.
5. Continuously monitor the temperature changes at different locations (workpiece surface,
tool-chip interface, tool flank, etc.) during the cutting operation.
6. Analyze the temperature data to understand the heat generation and distribution in the
cutting zone.
7. Use the findings to optimize cutting parameters, cooling methods, and tool materials to
minimize cutting temperature and prevent thermal damage to the tool and workpiece.

RESULT:
 INTRODUCTION TO COMPUTER NUMERICAL CONTROL I

Aim: Know the basic functions of a machine tool, concept of numerical control, historical development,
definition, advantages of CNC machine tools

Computer-aided Manufacturing (CAM) is the term used to describe the use of computerized systems to
control the operations at a manufacturing plant. These computerized systems assist manufacturers in various

operations such as planning, transportation, management, and storage. CAM helps manufacturers improve their
time to market capabilities, and create precise dimensions.

The History of Computer Numerical Control (CNC)

Computer numerical control is a modern concept in the manufacturing and production industries.

However, the concept of CNC harkens back to the basic idea of NC, or numerical control.
The idea of numerical control started when the automation of machine tools originally incoporated
specific concepts of programmable logic. In the beginning. the first NC machines were built back in the 1940s.
Slightly more advanced machines came along in the 1950s. These manufacturing machines were constructed
based on existing tools that were modified with motors designed to move the controls of the machine. These

controls followed specific points that were fed into the machine on punched tape. These early mechanisms were
soon improved with both analog and digital computers. The introduction of computer technology into the concept

of numerical control led to what we now know as computer numerical control.

Brief Introduction to Computer-aided Manufacturing

As a process, CAM is used after Computer-aided Design (CAD) or Computer-aided Engineering (CAE).

The model designed using CAD is sometimes used as the CAM input. This is why it is referred as CAD-CAM.
The functions of this combination are divided into two main categories:
Manufacturing Planning: In this process, the computer delivers information for production planning as well as

management. This may include:

Computer Aided Process Planning (CAPP)

Computer Assisted NC Part Programming

Computerized Machinability Data System

Work Standards Development

Inventory and Production Planning

Manufacturing Control: In the process, the computer is used to manage and control the physical operations of
the manufacturing plant. These may include:

Shop Floor Controlling

Process Monitoring and Controlling

Inventory Controlling
 Production Delivery Controlling

Benefits of CAD-CAM in Manufacturing

Today, every manufacturing plant uses at least a type of CAD-CAM system to control their operations.
Here are the various advantages they can avail by using these software applications.

Tmproves Machining Capabilities: By using a CAD-CAM system, manufacturers can improve their machining
capabilties. For example, when a manufacturer takes up a complex 3-axis machining task, they rely on the
combination software to create a tool path for machining projects such as molding. The CAM system automates
the process, and makes it easier for manufacturers to complete the project in time.

Improves Client Accessibility: The CAD-CAM software allows manufacturers to receive CAD files from their

customers. Ater receiving these files, they can set up the machining tool path, and pertorm simulations, which
help them calculate the machining cycletimes. The software allows manufacturers to minimize errors, execute

projects easily, and deliver products to the market within a shorter turnaround time.
Improve Productivity of CNC Machines: Mst CAM-CAD systems provide high-speed machine tool paths,
which help manufacturers minimize their cycle times, reduce tool and machine wear. High-speed tool paths
enable manufacturers to improve their cuting quality and accuracy. This ype of high- speed machining helps
improve the productivity of the CNC machine by more than 50%.
Reduce Material Wastage: As CAM-CAD software feature simulation features, it helps a manufacturer to
visually inspect the process of machining. This allows him to capture tool gouges, and collisions at an early phase.
This feature contributes to the overall productivity of a manufacturing set up. This also helps them eliminate
mistakes, as well as reduce material wastage.
 INTRODUCTION TO cOMPUTER NUMERICAL CONTROLII

AIM: To Know Evolution of CNC, advantages of CNC, limitations of CNC, features of CNC, machine control
unit (MCU) for CNC, classification of CNC machine tools; CNC machining centers: classification, features of

CNC machining centers

Co-ordinate system:
In order for the part programmer to plan the sequence of positions, moments, the cutting tool. Machine to
the WIP, it is memory to establish a standard axis system by which the relative positions can be specified. Two
axes "X & Y" are defined in the plane of the table, the z' axis in perpendicular. In this plane of the table the
vertical motion of the spindle controls the "z' direction. The positive and negative directions motion of the tool.

Programming methods

1) Incremental method
2) Absolute method

A B
1) Incremental Method:
In this method, every point is considered as origin from this point; the values are calculated, for example
Point A = (0, 0)

Point B (20, 0)
Point C = (0, 10)

Point D = (-20, 0)

2) Absolute method:
In this absolute system, the set point is considered as a reference point as from that point, all the values are
calculated, for example
Point A = (0, 0)

Point B = (20, 0)

Point C = (20, 10)

Point D = (0, 10)

Programming methods:
In CNC machines program are programmed by two methods.
1) Manual part programming

2) Computer assisted part programming

1) Manual part programming:
To prepare a part program using the manual method, the programmer writes the machining instruction is
must be hence, menu seript the instruction is must be prepared in a very precise manner because the typist
prepares the NC type directory from the Manu script some in various form expending on the machine tool and
tape format used.

2) Computer assisted part programming:

In the more complicated point and in contour application using manual part programming because an

extremely tedious basic and subject to errors. It is must more appropriate to employ the high speed digital
computer to assist the part programming languages system have been developed to perform automatically most of
the calculation which the programmer would otherwise be forced to do

PREPARATORY FUNCTIONS (G-CODE):

Preparatory functions are used for cutting operations like facing, turning, thread cuting, drilling, etc.

MISCELLANEOUS FUNCTIONS (M-CODE):

Miscellaneous functions are used for other than cutting operations like spindle ON/OFF, coolant
ON/OFF, tool change, etc

Preparatory Functions (G-Codes):

G00- Positioning at rapid speed; Mill and Lathe
GO1-Linear interpolation (machining a straight line); Mill and Lathe
G02-Circular interpolation clockwise (machining arcs): Mill and Lathe
G03- Circular interpolation, counter clockwise; Mill and Lathe
GO4-Mill and Lathe, Dwell
G09- Mill and Lathe, Exact stop
Gi0-Setting offsets in the program; Mill and Lathe

GI2-Circular pocket miling, clockwise; Mill

GI3-Circular pocket milling, counterclockwise; Mill
Gi7-X-Y plane for arc machining: Mill and Lathe with live tooling
G18-Z-X plane for arc machining; Mill and Lathe with live tooling
G19-Z-Y plane for arc machining; Mill and Lathe with live tooling
G20- Inch units; Mill and Lathe
G21- Metric units; Mill and Lathe
G27- Reference return check; Mill and Lathe
G28- Automatic return through reference point; Mill and Lathe

Page | 1 0
G29-Move to location through reference point; Mill and Lathe
G31 Skip function; Mill and Lathe

G32-Thread cutting; Lathe

G33-Thread cutting: Mill
G40 Cancel diameter offset; Mill. Cancel tool nose offset; Lathe
G41 -Cutter compensation left; Mill. Tool nose radius compensation left; Lathe
G42-Cutter compensation right; Mil. Tool nose radius compensation right; Lathe

G43-Tool length compensation; Mil

G44-Tool length compensation cancel; Mill (sometimes G49)
G50-Set coordinatesystemand maximum RPM; Lathe
G52-Local coordinate system setting: Mill and Lathe
G53- Machine coordinate system setting; Mill and Lathe
G54-G59-Work piece coordinate system settings #1 to #6; Mill and Lathe

G61- Exact stop check; Mill and Lathe

G65-Custom macro call; Mill and Lathe
G70- Finish cycle: Lathe
G71- Rough turning cycle; Lathe
G72-Rough facing cycle; Lathe
G73- Iregular rough turning cycle; Lathe
G73- Chip break drilling cycle; Mill
G74-Left hand tapping: Mill
G74-Face grooving or chip break drilling; Lathe
G75-OD groove pecking: Lathe

G76-Fine boring cycle; Mill

G76-Threading cycle; Lathe
G80-Cancel cycles; Mil and Lathe
G81 Drill cycle; Mill and Lathe
G82- Drill cycle with dwell; Mill

G83-Peck drilling cycle; Mill

G84-Tapping cycle; Mill and Lathe
G85- Bore in, bore out; Mill and Lathe
G86- Bore in, rapid out; Mill and Lathe

G87-Back boring cycle; Mill

G90 Absolute programming
G91 Incremental programming
G92-Reposition origin point; Mill
G92-Thread cutting cycle; Lathe

D-ao 11
 G94- Per minute feed; Mill
G95- Per revolution feed; Mill
G96-Constant surface speedcontrol; Lathe
G97-Constant surface speed cancel
G98- Per minute feed; Lathe
G99- Per revolution feed; Lathe

Miscellaneous Functions (M-Code):

M00-Program stop: Mill and Lathe

MO1-Optional programstop: Lathe and Mill
M02 - Program end; Lathe and Mill

M03-Spindle on clockwise; Lathe and Mill

M04-Spindie on counterclockwise; Lathe and Mill
MO5- Spindle off; Lathe and Mill
MO6- Tool change; Mill
MO8 Coolant on; Lathe and Mill

M09-Coolant off; Lathe and Mill

M30 - Program end, return to start; Lathe and Mill

M97 - Local sub-routine call; Lathe and Mill

M98 - Sub-program call; Lathe and Mill

M99 - End of sub program; Lathe and Mill

M00 - program stop

MO1 optional stopusing stop button

M02- end of program
M03 spindle on CW

M04 spindle on CCW

M05 -spindle off
M06- tool change
M07- flood with coolant
M08- mist with coolant
M09 coolant off
M17- subroutine end
M20-tailstock back
M21 - tailstock forward

M22 - Write current position to data file

M25 open chuck

M30- end of tape

Dago 12
M71 - puff blowing on
M72 - puff blowing off

M96 - compensate for rounded external curves

M97- compensate for sharp external curves

M98- subprogram call
M99- return from subprogram, jump instruction
M101 move x-axis home
M102 - move y-axis home

M103 - move z-axis home

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 Experiment
Title: Setting up of workpiece zero position and machining in Modular CNC Turning
machine
Objective: To learn to setupa CNC Turning machine and exccuting a part programme.

Procedure: To setup the workpiece zero point refer to Fig.I and the following steps should
be followed

Cylindrical (0, ) Z( )
Work piece
Too-Workpiece touching
positon for setting Z zero

Too-Workpiece touching *X(4)

positon for setting X zero

Operator

Fig.
1. Start the spindle
2. Manually move the tool to a safe distance from the workpiece
3. Now in jogging mode touch the workpiece by the tool as shown in Fig. 1 and set
respective axes to zero. For X axis, input the diameter of the workpiece in touchoff
dialog box and the machine will automatically set X axis to zero position.
4. Move the tool to safe distance.

Example of a CNC program for turning: Refer to Fig.2

Taper 10 mm

o 6 mm
Dia
Dia 12 5 mn
12.5 | Dla 11 mm|
Program:
NO1 G21;
N02 G7;
N03 GO X20;
N04 GO Z1
NOS GO X12;
NO6 G1 2-12 F50
N07 GO X13 Z-10;
N08 GO Z1;
N09 GO X11.5;
N10 G1 Z-12 F50;
N11 GO X12 Z-10;
N12 GO ZI;
N13 G1 Z-12 FS0;
N14 GO X12 Z-10;
NI5 GO Z1;
N16 GO X10;
N17 GI Z0 FS0;
N18 GI X11 Z-6 F50;
N19 GI X14;
N20 GO X20 Z2;
N21 M02;
 Experiment r
Title: CNC Programming and Simulation.

Objective: To write and simulate CNC Part program for three axes Milling machine.

CNC Part programme examples

Example 1: Write a CNC part programme to cut the part as shown in Fig.l from an
aluminium slab of 19 mm thickness and size 90 mm x 90 mm.

(20, 80) (70,80)

R10 R10
rmo, 70) (80,170)

0
(10, 45- Starting point
80,220)
10, 20)
R10
(20, 10)
(70,10)R10
(0, 0) 0
(all dimnsions are in mm)

Fig.l

Program code
NOI G21 G94:
NO2 G28 G91 Z0;
N03 G28 XO Y0;_
N04 M03 S1800;
NOS GO0 G90 X0 YO
FI0
N06 GOO Z10 F50;
NO7 GOO X10 Y45;_
NO8 GO1 Z-0.5 F50;
NO9 GO1 Y70;_
N10 G03 X20 Y80 RI0;
NII GO1 X70:
N12 G03 X80 Y70 RI0;

NI3 GOI Y20;

N14 GO2 X70 Y10 R10;

NIS GOIX20;_
NI6 GO2 XIO Y20 R10

N17 GO1 Y45;

NI8 GO0 210;
N19 G28 G91 Z0;
N20 G28 XO YO; _
| N21 MO5;
N22 M30;