Lab 2 Report

Waleed Wasim (5176694) (Selected Student Number for Program)

Exercise Conducted on:

Report Submitted on:

14 – OCT – 2016

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Table of Contents

Introduction:..........................................................................................................................................3
Description of Machines Used:..............................................................................................................3
CNC Program:........................................................................................................................................4
Accuracy & Surface Quality of the Program:.........................................................................................6
Conclusions:..........................................................................................................................................7

Introduction:

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CNC means Computer Numerical Control. This means a computer converts the design produced by
Computer Aided Design software (CAD), into numbers. The numbers can be considered to be the
coordinates of a graph and they control the movement of the cutter. In this way the computer
controls the cutting and shaping of the material.

Description of Machines Used:

We used bench top milling machines which were CNC for this experiment. These machines are
specifically designed for manufacturing only small parts or laboratory exercises since the milling
table has a range of 200 x 76 x 159 mm incorporating simultaneous XYZ movements. The spindle of
the machine is capable of speeds of 70-2800 rpm and a feed range of 0 – 200 mm/min.

CNC Program:

The structure of the program and the explanation of the codes used within the program are
mentioned within the program enclosed in round brackets

(Student Number 5176694)

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G90 (set absolute coordinates and metric)

G21

G00 X0.0 Y0.0 Z1.0 (move tool to start point)

G17 (set xy plane for arc)

F80 (set feed rate to 80mm/min)

(Roughing Operation)

G00 X-21.05 Y-16 Z1.0 (go to starting point)

G01 X-21.05 Y-16 Z-2.5 (starting to cut outer boundary)

G02 X-35.05 Y-7 R16

G01 X-35.05 Y7

G02 X-21.05 Y16 R16

G01 X-11 Y16

G03 X11 Y16 I11 J1

G01 X21.05 Y16

G02 X35.05 Y7 R16

G01 X35.05 Y-7

G02 X21.05 Y-16 R16

G01 X0 Y-19

G01 X-21.05 Y-16 (back to starting point)

G01 X-21.05 Y-14 (starting to cut left side inner boundary)

G02 X-7.05 Y0 I0 J14

G01 X-7.05 Y-14

G01 X-21.05 Y-14

G01 X7.05 Y-14 (move to right side)

G01 X7.05 Y0 (starting to cut right side inner boundary

G02 X21.05 Y-14 I14 J0

G01 X7.05 Y-14

G01 X3 Y-14 (cleaning)

G01 X3 Y3 (cleaning)

G01 X-3 Y3 (cleaning)

G01 X-3 Y-17 (cleaning)

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G01 X-6 Y-17 (cleaning)

G01 X6 Y-17 (cleaning)

G01 X6 Y-17 Z1

G00 X12 Y13 Z1 (move to next cleaning section)

G01 X12 Y13 Z-2.5 (cleaning)

G01 X12 Y13 Z1

G00 X-12 Y13 Z1 (move to next cleaning section)

G01 X-12 Y13 Z-2.5 (cleaning)

G01 X-12 Y13 Z1 (rough operation end)

(Finishing Operation)

G00 X-21.05 Y-17 Z1.0 (go to starting point)

G21

F50 (set feed rate to 50mm/mn)

G01 X-21.05 Y-17 Z-2.5 (starting to finish outer boundary)

G02 X-36.05 Y-7 R17

G01 X-36.05 Y7

G02 X-21.05 Y17 R17

G01 X-10 Y17

G03 X10 Y17 I10 J0

G01 X21.05 Y17

G02 X36.05 Y7 R17

G01 X36.05 Y-7

G02 X21.06 Y-17 R17

G01 X0 Y-20

G01 X-21.05 Y-17

G01 X-21.05 Y-13

G02 X-8.05 Y0 I0 J13 (starting to finish left inner boundary)

G01 X-8.05 Y-13

G01 X-21.05 Y-13

G01 X8.05 Y-13 (move to right side)

G01 X8.05 Y0 (starting to finish right inner boundary)

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G02 X21.05 Y-13 I13 J0

G01 X8.05 Y-13

G00 Z1 (move tool out of job then go to start position)

G00 X0 Y0

M30 (end of program)

Accuracy & Surface Quality of the Program:

After measuring the dimensions of the machined part it can be deduced that the codes written for
the machining were accurate to the design dimensions as can be seen from the following table:

Section Name Design Dimensions Part Dimensions

A 22 22.22
B 20 20.01
C 78 78.14
D 8 8.03
E 2.5 2.53

As can be seen from the table, the machined part dimensions measured are quite close to the
designed dimensions and the small variations between these values come within the range of
tolerance.

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The surface quality of the part can be improved upon by reducing the depth of cut and increasing
the speed of the spindle for the final finishing operation. This will result in better and smoother finish
of the part.

Conclusions:

During the 2nd lab session, students of MECH 935 performed milling operation using a Computer
Numerically Controlled Milling machines. The whole exercise included understanding the G-Code
structures that is the most common type that is being used within the industry, writing down a
program using G-Codes for the given design to be machined on a block of Plastic and the tool used
for that was the software “grblControl”. After writing down the program, the program had to be
executed on the CNC milling machine and produce the final desired part.

As a student of Mechanical and Manufacturing Engineering, this lab could be vital for students that
see their future within the manufacturing industry. A general knowledge of how G-Coding is done is
essential for an engineer since, nowadays, due to advent of modern technologies such CAD and CAM
tools, it is vital for an Engineer to have a certain degree of knowledge of these tools.