1.

0 WORKSHOP LEARNING OUTCOMES

At the end of the workshop sessions students should be able:

i) Construct a CNC and EDM machine programming according to machining instruction and
related tasks. (P3)

ii) Perform the CNC and EDM machines according to Standard Operating Procedure. (P4)

ii) Demonstrate the ability to work as individual and as a team to complete assigned tasks. (A3).

2.0 THEORY

2.1 INTRODUCTION OF CNC

Numerical Control is a method of automatically operating a manufacturing machine based on a code

of letters, numbers, and special characters. A complete set of codes for executing an operation is
called a program. These codes are translated into corresponding electrical signals for input to motors
which runs the machine. Computer Numerical Control (CNC) is the process of manufacturing
machined parts using a computerized controller to command motors which drive each machine axis.
The process is controlled by a computerized controller called Machine Control Unit (MCU). The MCU
generates, stores, and processes CNC programs. The MCU uses matars to drive each axis of a
machine toll and regulates its direction, speed, and the amount of time each motor rotates.

Advantage of CNC Over NC:

a) Reduction in hardware for adding functions.

b) New functions can be programmed into the MCU as software.

c) The CNC program can be written, stored, and executed at the CNC.

d) Any portion of an entered CNC program can be played back and edited.

e) Many Different programs can be stored in the MCU.

f) Several CNC machine can be linked together to main computer. This known as Direct Numerical
Control [DNC].

g) Several DNC systems can be networked to form Distributive Numerical Control system.

h) The CNC program can be input from zip, floppy disks, flash, portable external drive, or can be
downloaded from the network.
Type of Machine Motion Controllers in the MCU:

a) Fanuc.
b) Allen-Bradley
c) Okuma.
d) Mazak and others
e) GE.
f) Bendix

2.3 COORDINATE SYSTEM

2.4 CNC MILLING MACHINE
2.5 G CODES LIST
2.6 BASIC G FUNCTION

2.7 M CODE LIST

2.8 BASIC M-FUNCTIONS
3.0 APPARATUS AND EQUIPMENT

I) CNC Milling Machine

Ii) Aluminum cube bar work piece

Iii) Steel ruler / Vernier caliper

Iv) Machine hand tools

4.0 SAFETY PRECAUTIONS

4.1 PERSONAL SAFEGUARD

a. Wear approved safety glasses at all times in designated areas.

b. Wear safety shoes when working with heavy tools and equipments.

Keep long hair covered when operating or standing near machines.

d. Do not wear jewellery or loose clothing while operating or standing near machines.

e. Avoid skin contact with any cutting fluids or oils.

f. Do not operate any machines or equipments while under the influence of drugs (prescribed or
otherwise)

g. Always report any injury and apply first-aid treatment.

4.2 MACHINE AND TOOL HANDLING SAFEGUARDS

a. Store tools in their appropriate tool trays and racks.

b. Keep tools sharp and in good working condition.

c. Ensure that safety guards and devices are in place and working before operating any machine.

d. Keep all electrical and mechanical panels secures in place.

e. Do not handle loose wires or electrical components. f.

Check that all oil levels are maintained.

g. Check that all compressed air equipment is in good working condition.

h. Do not use compresed air to clean machines slides.

I. Keep tools, parts and any other items off the machine and part.

j. Use gloves when handling tools by their cutting edges.

k. Never use gloves when operating a machine.

l. Check that the machine is electrically sound and use lock-out tag-out practices.

m. Check that all lights in the machine work area are in good working condition.

n. Keep clear from obstructions and sharp tools when leaning into the machine area.

4.3 SAFETY MACHINING PRACTICES

a.In case of any emergency while operating a machine, immediately press the EMERGENCY STOP
button.

b.Keep hands away from the spindle while it rotating.

c. Do not open the electrical panel or control doors.

d. Keeps hand clear of all any moving machine components. e.

Check each tool for possible collisions with the part or machine components before starting any
operation.

f.Do not operate controls unless you have been properly instructed about the EMERGENCY STOP
button, FEED

HOLD button, SPINDLE STOP button and the various other operation functions.

g.Use caution to avoid inadvertently bumping any CNC control buttons.

h.Prove out new programs in DRY RUN mode before actual cutting.

i.Setup the work holding device and cutting tools as rigidly as possible.

j.Do not remove chips or debris by hand or while the spindle is ON or in operation.

k.Check that all feeds and speeds do not exceed recommended values.
l. Maintain continuous flow of coolant to the cutting tool when it is required.

m. Always consult with an authorised person if you are uncertain or unfamiliar with any operation.

5.0 PROCEDURE AND PRACTICAL TASKS

5.1 PROCEDURE

a. Examine the drawing

b. Using suitable coordinate system, determine the coordinates of important points on the diagram
(of X, Y and R)

c. Based on the coordinates, plan the machining and write the program using G codes

d. Determine the tools to be used

e. Turn on power supply

f. Store the program into the memory

g. Mount the tools and work piece to the machine

h. Measure and input the tool geometry offset value

i. Set the work piece zero point j.

Check the program by carrying out dry run operation

k. Check the machining condition by carrying out test cutting

l. Machine the work piece in automatic operation

m. Product is completed

5.2 COMPENSATION FUNCTION

G40 Tool radius compensation cancel

G41 Tool radius compensation left

G42 Tool radius compensation righ

EXERCISE 1
7.0 CONCLUSION AND RECOMMENDATION

CNC milling is a manufacturing process that uses computer-controlled machines to shape and cut
materials, such as metal, plastic, and wood, into precise and complex shapes. The process involves
the use of a rotating cutting tool that removes material from the workpiece to create the desired
shape.

CNC milling offers several advantages over traditional milling methods, including greater precision,
repeatability, and speed. It allows for the creation of complex geometries and shapes that would be
difficult or impossible to achieve with manual milling. CNC milling machines also require less
operator intervention, reducing the risk of errors and increasing productivity.

However, CNC milling also has some limitations. The machines can be expensive to purchase and
maintain, and they require skilled operators to program and operate them. Additionally, the process
may not be suitable for certain materials, such as those that are too brittle or too soft.

Overall, CNC milling is a valuable tool for modern manufacturing processes, offering high levels of
accuracy, flexibility, and efficiency. Its use is likely to continue to expand in the future as technology
advances and new applications are discovered.

I recommend to get the best results from CNC milling, it's essential to optimize your designs for the
process. Consider factors such as the material properties, tooling options, and machining tolerances
to ensure that your design can be manufactured efficiently and accurately.

9.0 REFERENCE

i) https://www.hubs.com/knowledge-base/what-is-cnc-milling/

ii) https://www.3erp.com/manufacturing-technology/what-is-cnc-milling/