Heritage Institute of Technology

Department of Mechanical Engineering

LAB MANUAL

Advanced Manufacturing Lab

(MECH – 4211)
 List of Experiments
Advanced Manufacturing Lab MECH 4211
1. Study of CNC Lathe and preparation of report covering machine capacity
and specification.

2. Learning Basic Operations of ACE Micromatic CNC Lathe

3. Facing, Chamfering & Turning of a component in CNC Lathe through a

program.

4. Stock Removal, Radius Turning and Thread cutting in CNC Lathe through
a program.

5. Study of EDM machine and preparation of report covering machine

capacity and specification.

6. Learning Basic operations of EDM machine.

7. Machining of a component in EDM.

8. Study of robot and preparation of report covering its capacity and

specification.

9. Programming of the robot for pick and place operations

10. Operation of the robot through a program

 Heritage Institute of Technology
Department of Mechanical Engineering
Advanced Manufacturing Lab

Experiment No. : MECH 4211/ 1 Date:

Experiment: Study of CNC Lathe and preparation of report covering machine capacity and specification.

Objective: To study the construction of ACE Micromatic CNC Lathe and prepare a report describing the
following features, components, systems and sub-systems.

A. Machine Specification:
1. Capacity, Spindle swing, travel of X & Z axes.
2. Range of Spindle speed, feed rates in X & Z axes.
3. No. of tools in turret.
4. Connected Load, required voltage. Allowable variations in voltage and frequency

B. Mention the following for each consumable (like Hydraulic oil, Lubrication oil, coolant) required
for running the machine:
1. Description and Specification
2. Major Supplier
3. Quantity
4. Top up/ replacement cycle.

C. Draw a sketch of the machine, identify the following components of the machine and write short
note on each
1. Head Stock
i) Spindle details
ii) Chuck details, chuck actuation mechanism
2. Tailstock
3. X-axis slide
4. Z-axis slide
5. Turret- actuation mechanism

D. Write short note on the following Auxiliary systems of the machine

1. Control System
2. Electrical system
3. Hydraulic system
4. Lubrication system
5. Coolant System
Student’s signature & name: Roll No.
 Heritage Institute of Technology
Department of Mechanical Engineering
Advanced Manufacturing Lab

Experiment No. : MECH 4211/ 2 Date:

Experiment: Learning Basic Operations of ACE Micromatic CNC Lathe

Objective: Learning various functions on the control panel and operating the CNC machine without any
component (dry run).

A. Get familiarized with the buttons on the control panel.

B. Identify and operate the following:

1. Start / stop switch in the stabilizer.
2. EMERGENCY STOP switch
3. CNC ON/ OFF switch
4. Foot switch for Opening & Closing of chuck
5. Foot switch for forward and retraction motion of tailstock
6. Machine reset and Machine setup switch
7. Cycle Start / Stop switch
8. Mode selection switch
9. Feed override switch
10. Rapid override/ feed selection switch
11. Spindle Speed override switch
12. Jog Switch
13. Spindle control switch
14. Turret index switch
15. Coolant ON/ OFF switch.
16. Dry run switch
17. Program Test switch

C. Identify various display units.

D. Identify tool position no. on the turret and index the turret.
E. Identify the X-axis and Z-axis of the machine and move turret along X & Z axes.
F. Set machine off-set for a particular job.

G. Prepare a report describing the function of the above switches.

 Heritage Institute of Technology
Department of Mechanical Engineering
Advanced Manufacturing Lab (ME – 791)

Experiment No. : MECH 4211/ 3 Date:

Experiment: Facing, Chamfering & Turning of a component in CNC Lathe through a program.

Objective: Learning to write CNC program for facing, chamfering & turning and carrying out the
machining operations on a component through the program.

Get familiarized with G codes and M codes of the ACE Micromatic CNC lathe. (refer to pages 7.1 to 7.12
of the Instruction and Parts Manual)

Program for facing

Material : Mild steel

Work piece diameter = 35 mm
Material to be removed from end by facing = 1 mm in two cuts each 0.5 mm
Feed rate = 0.1mm/ rev
Cutting speed = 165 m/min (For work dia of 35 mm , spindle speed is 1500 rpm)

O0002; (program name)

N1 G 0 X 0 Z 0 T 0; (Sends the tool to machine home position)
T 0 5 0 5; (Tool is in station no. 5 of the turret and takes off-set in line 5 of off-set table,
Work piece zero becomes the new 00 position, 2mm stock to be removed from
face)
M 3 S 1500; (Spindle starts in CW direction at 1500 rpm)
G 0 X 40.0 Z 4.0 M 7; (G0 Rapid movement of the tool to X=40.0, Z=4.0 position, Coolant switches on)
G 0 Z 0.5; (Tool moves in –Z direction towards work piece by 3.5mm, i.e. the tool is 0.5mm
from work piece zero)
G 01 X 0 F 0.1; (G01 is liner interpolation for the facing operation, feed is 0.1 mm/ rev, depth of
cut=1.0-0.5=0.5mm. While remaining at Z=0.5mm position the tool moves in –X
direction to position X=0. This is facing 1st cut)
G 0 Z 1.5; (Tool retracts from work piece face by 1.0mm in +Z direction in rapid motion)
G 0 X 40.0; (Tool moves in +X direction to X=40.0 while remaining at z=1.5mm position)
G 0 Z 0; (Tool moves in –Z direction towards work piece by 1.5 mm, i.e. the tool is 0 mm
from work piece zero)
G 01 X 0; (Feed need not be keyed in again, it will be taken as 0.1 mm/ rev, depth of
cut=0.5mm. While remaining at Z=0.0 position the tool moves in –X direction to
position X=0. This is facing 2nd cut)
G 0 Z 1.0 M 9; (Tool retracts from work piece face by 01.0 mm in +Z direction in rapid motion,
coolant switches off)
M 5; (spindle stops)
G 0 X 0 Z 0 T 0; (Sends the tool to machine home position)
M 30; (Program ends)

G 01 X 0; command is supposed to take the tool to job centre line, but due to finite tool nose radius the
tool point touching the face does not reach the job centre line. This will leave a pip in the face centre
line zone.

‘G 01 X -1.0’ in place of ‘G 01 X 0’ takes the tool point to the centre line for a tool nose radius of 0.4mm
Facing, chamfering & turning.

Program for facing, chamfering and turning.

Material : Mild steel Work piece diameter = 35 mm
Material to be removed from end by facing = 1 mm in two cuts each 0.5mm
Material to be removed from OD by turning = 1 mm on dia in one cut
Chamfer = 1 x 45 deg. Feed rate = 0.15mm/ rev
Cutting speed = 165 m/min (For work dia of 35 mm , spindle speed is 1500 rpm)

O0003;
N1 G 0 X 0 Z 0 T 0;
T 0 2 0 2;
M 3 S 1500;
G 0 X 40.0 Z 3.0 M 7;
G 0 Z 0.5;
G 01 X -1.0 F 0.15;
G 0 X 40.0 Z 1.0;
G 0 Z 0;
G 01 X -1.0;
G 0 Z 1.0;
G 0 X 32.0;
G 01 Z 0;
G 01 X 34.0 Z -1.0; (cuts 1x45 deg chamfer)
G 01 Z -10.0; (turns the OD)
G 01 X 36.0 M 9; (tool retracts)
M 5;
G 0 X 0 Z 0 T 0;
M 30;

Report: Draw neat sketch of the following

1. The component to be machined with dimensions and identify the “Work Centre”.
2. Tool tip movement path in dotted line w.r.t. the component for facing, chamfering and turning

Student’s signature & name: Roll No.

 Heritage Institute of Technology
Department of Mechanical Engineering
Advanced Manufacturing Lab (ME – 791)
Experiment No. : MECH 4211/ 4 Date:

Experiment: Stock Removal, Radius Turning and Thread cutting in CNC Lathe through a program.

Objective: Learning to write CNC program for Facing, stock removal, chamfering, radius turning, OD
turning and thread cutting and carrying out the machining operations on a component through a
program.

Get familiarized with G and M codes (refer to pages 7.1 to 7.12 of the Instruction and Parts Manual)

Program for facing, stock removal, chamfering, radius turning, OD turning and thread cutting.
Material : Mild steel
Work piece diameter and length = 35 mm and 50 mm
Material to be removed from end by facing = 1 mm in one cut
Material to be removed from OD by turning = 1 mm on dia in one cut
Chamfer = 1 x 45 deg. Feed rate = 0.15 mm/ rev
Cutting speed = 165 m/min (For work dia of 35 mm , spindle speed is 1500 rpm)

O0007;
N1 G 0 X 0 Z 0 T 0;
T 0 2 0 2;
M 3 S 1500;
G 0 X 40.0 Z 3.0 M 7;
G 0 Z 0;
G 01 X -1.0 F 0.15;
G 0 X 35.0 Z 2.0;
G 71 U 1.0 R 0.5; (G71 is stock removal cycle parallel to Z-axis.
G 71 P 100 Q 120 U 1.6 W 0.1 F0.25; G71 U (d) R (e)
G 71 P (ns) Q (nf) U(u) W(w) F(f) where
d = depth of cut e = Tool retract amount
ns = starting block no. of finished profile
nf = end block no. of finished profile
u = finishing allowance on X-axis
w = finishing allowance on Z-axis
f = feed value
N100 G 0 X 15.0; (Co-ordinates of points P1, P2, P3, P4, P5 & P6 are to be inserted in
G 01 Z 0 F0.15; sequence)
G 01 X 18.0 Z -1.5; (cuts 1.5 x45 deg chamfer)
G 01 Z -21.0;
G 02 X 26.0 Z -25.0 R 4.0; (G02 :Circular Interpolation in CW direction, Final XZ position, Rad. 4mm)
G 01 X 29.0; (facing operation)
G 03 X 35.0 Z -28.0 R 3.0; (G03 :Circular Interpolation in CCW direction, Final XZ position, Rad. 3mm)
G 01 Z -45.0; (OD turning)
N 120 G 01 X 37.0; (Tool retracts slowly)
G 0 Z 2.0 ; (Tool goes to position X 37.0 Z 2.0)
G 0 X 15.0;
G 01 Z0 F0.15; (Finishing cycle starts)
G 01 X 18.0 Z-1.5;
G 01 Z-21.0;
G 02 X 26.0 Z-25.0 R 4.0;
G 01 X 29.0;
G 03 X 35.0 Z-28.0 R 3.0;
G 01 Z -45.0;
G 01 X 37.0;
G 0 Z 2.0 M9;
M5;
N5 G 0 X 0 Z 0 T 0;
M 01;
T 0505; (Tool no. 5 selected for threading cycle, Offset from line 05)
M3 S 1000;
G0 X 21.0 Z 4.0 M7;
G 76 P 020060 Q 100 R 50;
G76 X 15.44 Z -20.0 P 1280 Q 200 F 2.0; (G76: Threading cycle Format is
G76 P m r a Q(dmin) R(e);
G76 X(u) Z(w) P(k) Q(d) F(l); where
m= No. of idle pass reqd to cut material from spring back
r= Tool retract amount; For 90 deg retract r=00
a= Angle of tool tip = 6o deg for metric thread
dmin=Minimum depth of cut in MICRON
e=Finishing allowance in MICRON
Depth of thread= 0.64 x Pitch (=2mm) u=Minor dia for external thread/ Major dia for int thread
= 1.28 mm w=Thread length
Minor dia= Major dia – 2 x depth of thread k=Depth of thread in MICRON
= 18.0 – 2 x 1.28 = 15.44 mm d= Depth of cut in first pass in MICRON
l=Lead =pitch for single start thread = 2 mm)
G 0 X 21.0 Z 4.0 M9; (Tool goes back to X=21.0, Z=4.0)
M5;
G 0 X 0 Z 0 T 0;
M 30;

Report:
Draw a neat sketch of the component to be machined with dimensions and identify the “Work Centre”.
Draw the tool tip movement path in dotted line w.r.t. the component for
(a) facing, stock removal, chamfering
(b) radius turning, OD turning and thread cutting.

Student’s signature & name: Roll No.