CHAPTER-1

INTRODUCTION

I had the opportunity to study both conventional and CNC machines, but have

given more stress on the CNC machines, owing to their emerging importance. A

general description of conventional lathe and milling machines has been given. The

concepts of Computer Numerically Controlled machines have been explained in

greater detail.

Figures 1.1 CNC Machine

After its foundation from 1947, “NPL has made its valuable contribution to the

community, industries as well as to building edge of enlightenment in areas of

engineering”.

WORKSHOP AREAS

 Cutting and welding

 Electroplating

 Designing

 Working on sheet metal

 Carpentry capacity

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  Conventional machines section

 CNC machines section

CONVENTIONAL MACHINES SECTION

In this section, some of the machines are :

Bandsaw-

The bandsaw is useful for cutting stock to size and roughing out shapes. It cuts

curved shapes very well.

Belt sander-

Belt sander is used to remove rough edges. It makes use of an abrasive riding

belts. Effective on wood ,plastic and most metals.

Drilling machine-

The drill press is mostly used for drilling holes, reaming, countersinking

etc.and other hollow surfaces.

Power hacksaw-

A type of hacksaw powered either by its own electric motor or connected to

an engine.

DRILLING MACHINE POWER HACKSAW

For measurement and testing, micrometers, calipers, etc. as well as for sheet

electroplating, metal work, etc., several other machines are used.

Surface grinding machine – High precision surface finish is provided by this

machine tool. The machine has highly adaptable grinding wheel which revolves in the

spindle. The part or work-piece is fed by a straight table placed under the grinding

wheel.

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 Figures 1.2: Drilling Machine Power Hacksaw

Slotting machine – It is analogous to the vertical shaper machine. For machining

straight, smooth surfaces, this machine is commonly used.

Figure1.3: Slotting machine

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 CHAPTER-2

MANUFACTURING OPERATIONS TO BE CARRIED OUT ON A LATHE

 Turning – Reduction of part or work piece’s diameter to a desired dimension.

 Facing - Creating a smooth, flat and accurate face perpendicular to the axis of

a part or workpiece on lathe machine.

 Parting - Shallow and fine as compared with a turning tool. Parting is intended

to make constricted grooves.

 Drilling - Accurately concentric holes are also drilled with the axis of a

cylindrical work-piece on lathe machine.

 Boring - An operation which is intended to enlarge a hole with an SPCT

(Single-Point Cutting Tool).

 Threading – Internal and external threads is formed by the use of a tap and a

die respectively.

Fig 2.1: Lathe

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TYPES OF LATHE MACHINES

The most commonly used lathe machines - Bench Lathe/Centre Lathe/Engine Lathe

Tool-room Lathe –

Lathe enhanced for tool room work. This lathe has all possible features that

may be misplaced from less costly models, such as a taper attachment, collet closer,

and others.

Capstan lathes and Turret lathes –

These lathes are used for tedious manufacturing of identical work-pieces.

Multi-spindle lathe –

These lathes have an automated control system and having one or more spindle.

CNC LATHE

Cnc lathe are swiftly replacing the older production lathes due to their ease of setting

and operation. The job may be designed by the Computer-aided-manufacturing(CAM)

process, the design of the processed job be uploaded to the machine and once set and

trailed the machine will continue to turn out parts under the supervision of a machine

operator.

MILLING MACHINE

Milling is one of the most versatile machining operation and most of the shapes can

be produced with the help of it. In the milling operation the milling cutter with its

several edges at its outside is being fixed on the vice and being rotating on the armour

and the job being fixed brought in closer to it.

If “f ” is the feed velocity of the table in mm/min, the effective feed per tooth in mm

will be f/(NZ),where N is the cutter rpm and Z is the number of teeth in the cutter.

The material removal rate per unit width of the job is given by fd.

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 Figure 2.2 Milling machine

Classification of Milling Cutters

Figure 2.3:classification of milling cutter

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OPERATIONS TO BE CARRIED OUT ON MILLING MACHINES

Figure 2.3 Operations Done On Milling Machines

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SEVERAL COMMON CNC CONTROL SYSTEMS

 FIDIA

 DECKEL

 SINUMERIC

 HINUMERIC

 ECS

 LECS

 HEIDENHAIN

 GILDEMEISTER

 A CNC Milling center by DECKEL

 NUM

 SELCA

 MARPOSS

 Z-16

 FANUC

 FAGOR

BASIC TERMS ASSOCIATED WITH CNC MACHINING

Machine Zero –

It is a point at the origin of the machine’s coordinate measuring system. This

point is taken as a reference for all the axis movements and measurement of other

dimensions. Machine zero is related with the origin of CMS (co-ordinate measuring

system).

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 Figure 2.4 Machine Zero

Machine-Reference Point –

It denotes to the starting point of return for the benefit of feedback/ measuring

systems. The feedback/measuring system has to be adjusted by indicating this point

on each axis, whenever a CNC machine is switched ON.

Work Zero –

This is the origin for measuring of dimensions of parts. The programmer is

allowed to choose it anywhere on the drawing.

Axis Designation –

The Electronic Industries Association (EIA) RS 274-B standard is used for

designation of axis for each machine tool. This conforms to ISO Recommendations

R831. “Left hand rule” technique is used for the terminology of the X, Y and Z axis

(main axes). The orientation of X-axis is indicated by the thumb; the Y-Axis is

indicated by the index finger, and The Z-axis is indicated by the middle finger points.

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Tool and tool offset –

The particular tool and tool offset in the program is called by T function. The

data entered in the coordinate system preset block is corrected by the tool-offset. It is

very convenient to set up the tools and make alterations in work-piece size using the

tool offsets.

Spindle speed –

It is the rotating frequency of the spindle of the machine, measured in RPM

(Revolutions/minute). Depending upon the material being cut, the preferred speed is

to be determined. The quality of the surface finish and the tool life is affected by

using the accurate speed of spindle for work-piece material as well as for tools.

Feed rate –

It is the velocity at which the cutter is fed in advanced against the part or

work-piece. For turning and boring, it is described in millimeters per revolution

(distance per revolution). It is described in millimeters per minute (distance / time) for

the purpose of milling.

Cutting Speed –

It is defined as the speed (or rate) that the material moves towards the cutting

edge of tool, regardless of the process of machining used.

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 CHAPTER-3

CNC MACHINES’s CONSTRUCTION DETAILS

Fundamentals of motion transmission

In a CNC machine, the connection between the screw and the nut is through

an endless stream of re-circulating steel balls, replacing sliding friction threads with

rolling friction. Greater efficiency, reduction in wear and tear and reversibility are the

main advantages.

Figure 3.1 Elements of motion transmission

Hydrostatic Slide-ways

An air or oil is pumped into small pockets machined into slides which are in

contact with the slide-ways in hydrostatic slide-ways,

CNC machines has an in-built computer system that allows the operator to

read, analyze, and edit the programmed information. The computer works on a binary

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code value, 0 and 1 code is used for information and processing respectively in CNC

machines. Unique in-built software gathers the user entered program or language and

convert it into machine language and the machine moves the tool by its servomotors.

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CNC MACHINES WORKING

1. Modes of Operation

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xiv
Manual operation

CNC PROGRAMS PROCESSING

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 CONCLUSION

The significance of milling and lathes machines, although these all are

conventional, can not be challenged. These types of machines have shown a vital role

to bring the revolution in industrial field and placed the foundations. The conventional

machines are required in small quantities while the CNC machines must be increased

to enhance the quality and quantity of production.

 Less trained / skilled personnel can drive the CNC machines.

 Similarity of the products manufactured depends on the ability of worker.

 CNC machines can produce numerous products, which are very analogous and

accurate.

 Conventional machines provides very less chances for major improvement.

 CNC machines can be updated by using improved software configuration to

operate the machines.

 Conventional machines are required with very highly skilled operators to

work.

 One worker cannot drive more than one conventional machine at a time.

 A single person can control various CNC machines and work themselves.

 Conventional machines are very tough to run for some hours. The worker has

to constantly focus on the part in hand.

 CNC machines can be used continuously for long intervals and only need to

be switched off for occasional maintenance.

 Conventional Machine CNC Machine.

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 REFERENCE

 www.nplindia.org

 www.wikpedia.org

 www.fortune.com

 www.headland.com

 www.machinetoolhelp.com

 www.cncezpro

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