1.

0 TITLE

CNC Milling (Non Traditional Machining)

2.0 OBJECTIVE

A basic NC program was design for CNC milling

A product was machined using the CNC milling

3.0 INTRODUCTION

Non-traditional manufacturing (NTM) process can be defined as process that removes excess
or unwanted material. There are four basic group of material removal using NTM processes
which are chemical, electrochemical, thermal and mechanical. In this experiment, CNC
milling machine are used in order to carry out the main objective.

4.0 THEORY

Milling can be defined as a machining process that use rotary cutters to remove undesired
material from work piece advancing in a direction at an angle with the axis of tool. Milling
can be done with a wide range of tools, which the original one is the milling machine. Milling
machine is used to machine a solid material while numerical control is a form of
programming automation in which the process is controlled by numbers, letters and symbols.

In CNC machine tools, the instructions are stored as a program in a micro-computer attached
to the machine. The computer will also handle the control logic of the machine, making it
more adaptable than earlier hard-wired controllers. In the manufacturing industry, there are
plenty of CNC machine. There are CNC laser cutting, CNC press machine, CNC turning and
etc. The type of CNC machine we used in this experiment is the CNC milling machine.

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There are 6 important elements that are usually present in a CNC system. These systems are:

1. Part program: series of coded instructions required to produce part of work piece.
These are the important codes is part program:

Codes Address For

A Angular dimension around x-axis
B Angular dimension y-axis
C Angular dimension around z-axis
nd
D Angular dimension 3 feed function
rd
E Angular dimension around 3 feed

function
F Feed function
G Preparatory function
H Unassigned
I Distance to arc center to x
N Sequence number
O References rewind stop
P Third rapid traverse dimension
Q Second rapid traverse dimension
R First rapid traverse dimension
S Spindle speed function
T Tool function
U Secondary motion dimension parallel to X*
V Secondary motion dimension parallel to Y*

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Here the main function that always used in CNC Milling Machine:

Preparatory function (G)

It is function that involves the movement of machine axes and also its
associated geometry. These are some example of this function:

Code Function
G00 Rapid traverse
G01 Line interpolation
G02 Circular interpolation (clockwise)
G03 Circular interpolation (anti-clockwise)
G04 Dwell
G05 Delay
G06 Parabolic interpolation
G33 Thread cutting
G53 Deletion of zero offset
G64 Change in feed rate of speed
G80 Canned cycle cancelled

Miscellaneous function (M)

It is the function that operates some of the controls in the machine tools
and affects the running of the machine. These are some of the
examples:
Code Function
M00 Program stop, spindle and coolant off
M01 Optional programmable stop
M02 End of program
M03 Spindle on (clockwise)
M04 Spindle on (anti-clockwise)
M09 Coolant off
M10 Clamp
M31 Interlock by-pass
M68 Unclamp piece art

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 2. Program input devise: the mechanism for part programs to be entered into the CNC
control.

3. Machine control unit: acts as the heart and the main control of CNC system.
4. Drive system.
5. Machine tool.
6. Feedback system: uses position and speed transducer to continuously monitor the
position at which the cutting tool is located at any given time.

CNC milling machine also consist of coordinate systems which are important in order to
produce a good product. The function of this coordinate system is:
To locate tool changing points
To locate tooling or fixtures
To specify the location on the part for the machine-tool

The cutting tools that are used for CNC milling machine are in different variety. Most of the
machine use carbide insert end mill as its basic cutting tool. Face mill cutting tools is another
example of CNC cutting tool which function to flatten larger surface quickly and with
excellent finish. While a tool holder held the cutting tools that fits in the spindle.

Figure 1: Face Milling Cutting Tool Figure 2 : Tool Holder

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CNC milling machine also have its own advantages and disadvantages:
Advantages Disadvantages
Complex geometries are possible Large amount of energy
Extreme surface finish Unwanted distortion
Tight tolerance High maintenance
Little or no burring Expensive
Brittle material with high hardness
can be machined
Mass produce

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5.0 APPARATUS

CNC Controller

Working Table

Figure 3 : CNC Machine

Figure 4: Vernier Caliper

Figure 6: Lubricating Oil Figure 5: Cutting Tools

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6.0 INDUSTRIAL APPARATUS

Figure 7 : DATRON M10 Pro

This is a vertical mounting type of CNC machine
There are few application involves such as:
- A tight tolerance that require high speed and precise dimension.
- For rapid and high volume material removal.
- Aerospace and electromechanical parts.

Figure 8: Vertical EMCOMILL 750 CNC Machine

This machine is equipped with a motor spindle with a tool magazine that can hold 20
to 30 tools.
It is ideal for various applications because of its high thermal resistance and controlled
cutting precision made from up to date technology. It is engineered with a two-arm
rapid changer and an optional table on the 4th axis.

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 Figure 9: CNC Boring Mill / Horizontal

130 mm whirling / 170 mm milling x 6000 mm

( 5.12 " whirling / 6.69 " milling x 236 ")
Single screws (3 zone screws): barrier screws, twin screws, splines
Mixer sections
Machine dimensions : size 14.8m x 4.7 x 4.5m
Weight:36 metric tons

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7.0 EXPERIMENTAL PROCEDURE

7.1 NC Programming
1 Firstly, the NC Programming of the specimen which is to design a sport rim was done
by using CAM method in CATIA V5R21 Software.
2 The CAM was set to rough and finishing while the ball end tool was selected as the
machining tools.
3 The specimen (54mm x 54mm) was designed with 4 holes 4x10 PCD.
4 The edge of 3D axis (X, Y and Z axis) was determined after the rough stock is created
and one point was set for the origin point or datum.
5 Setting of the axis was set up by using the concept of right hand rule where Z-axis is
the spindle.
6 Once the design of specimen is done, the file is saved in save management folder to
avoid the data loss and transferred to USB drive.

Figure 10 : Design process using CATIA Software.

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 7.2 Download File to Controller
1. The CNC controller was switched on.
2. After that, the design of the specimen is transferred and downloaded to the controller.
3. The specimen was placed on the working table at and cutting tool for rough cut is
mounted.
4. The machine is ensured to be clean.
5. The tool was set up to move in circular for rough cut process while move radially for
the finishing process.

Figure 11: CNC Controller Tool Setting

7.3 Work Datum Setting and Machining

1 The specimen is placed horizontally on the CNC machine which the positive Z-axis is
facing to the spindle.
2 Vernier caliper was used to locate the edge of CNC machine.
3 Then, the cutting tool was set at the origin point.
4 Before running the machine, the specimen was sprayed with a lubricating oil to avoid
possible damages during the cutting process and to have a better surface finish.
5 Lastly, the machine was switched on to start cutting process.

Figure 12: Cutting process.

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6 All the dusts that are produced from the work piece during the cutting were cleaned
off using a brush during and after the cutting process.
7 The specimen was done and ready for inspection.

Figure 13: Cleaning the machine using brush.

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 8.0 RESULTS AND DATA ANALYSIS

Figure 14: Side View

Figure 15: Top View

Figure 16 : Final Product

Figure 17 : Isometric View

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 8.1 NC Program Code ( G-Code )
N1 G49 G64 G17 G80 G0 G90 G40 G99
(TOOL DATA : T1 END MILL D 1 )
N2 T0001 M6
N3 X49.601 Y59.294 S70 M3
N4 G43 Z9. H1
N5 G1 G94 Z-1. F300.
N6 X50.809 Y54.
N7 X54. F1000.
N8 Y37.38
N9 X53.619 Y38.5
N10 X53.553 Y38.651
N11 X51.363 Y42.724
N12 X51.273 Y42.863

N5282 X26.898 Y31.874 F1000.

N5283 X26.994 Y31.838
N5284 X27.079 Y31.858
N5285 X27.157 Y31.959
N5286 X27.159 Y32.034
N5287 X27.116 Y32.114
N5288 X27.026 Y32.16
N5289 X26.951 Y32.155
N5290 X26.894 Y32.123
N5291 X26.839 Y32.021
N5292 X26.848 Y31.943
N5293 X26.858 Y31.929
N5294 Z0
N5295 G0 Z5.
N5296 M5
N5297 M30
N5298 M2
N5299 M30

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9.0 DISCUSSION

In this experiment, the students were conducted to design a basic NC program for CNC
milling and machine a product using the CNC milling. The CNC milling is controlled by the
centroid control, is an intelligent PC based CNC that eliminates many typical limitations of
other control. The centroid control can be commanded in 3 axis configurations.

Furthermore, CATIA software is used to make the design of our product which is a sport rim.
Given by the our supervisor is a square of Perspex with 54mm length, 54mm width and 15mm
thickness as the material used for the fabrication.

After we finished the design, we transfer the coding that we made using ISO NC programmed
to the CNC milling machine. All the coding process involves fabricate the sport rim from the
beginning to the end are all in the form of codes. In here we learned that wrong coding input
will result in wrong process which will damage the fabrication of the sport rim. Hence to
prevent this happen, we run a simulation on the CNC screen and the errors can be detected
before real fabrication process start on the Perspex. After the final coding has been confirmed,
the CNC milling machine will start running according to the codes and orders given. The
orders are cutting, drilling, island, pocket, cutting tool, cutting fed cutting speed, spindle
speed and more that is suitable to make the sport rim.

After the CNC machine finished all the orders, the product which is the sport rim was
perfectly done. The dimension of the sport rim is perfectly done. The reason is, the cutting
tool was positioned (0, 0, 0) at the left bottom of the square Perspex. The sport rim we
designed was more complex because of the detail features, and takes a longer time to finish it.

The surface finish of the sport rim is considerably good even we used a 4mm tool bit. The
CNC machine we used was manually when it comes to change tool bit. We totally forgot we
need to change the tool bit when the finishing part comes. Hence, the product that we have
done might achieved a better surface finish if we change a smaller tool drill bit.

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10.0 CONCLUSION

In our conclusion, a basic NC program was design for CNC milling and a product was
machine using the CNC milling. Plus, all about nontraditional machining which focused on
CNC milling was been understood perfectly. The finished product which is the design of sport
rim using Perspex was done. Furthermore, to use the CNC milling, it is important to
understand the coding that used by the machine which mainly miscellaneous function (M) and
preparatory function (G). The CNC machine is able to produce a complex of shapes due to the
motion of the machine which able to move in 3 axes which are the X, Y and Z axis. The
advantages of using nontraditional machining; CNC milling machine compare to the
traditional ones, it can do the complex geometries product even conducted non skilled worker.
In addition, it can mass production and have extreme surface finish.

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11.0 RECOMMENDATION

1 To compare different result, the material of the work piece should be varied.
2 The CNC milling machine at the workshop should be installed with side cover to
avoid the cutting waste (chips) spread to the student while the experiment is running.
3 The user of CNC milling machine should wearing protective gear. Example, goggles
to protect the eyes from the flying chips.
4 The cutting tool diameter should be varied in order student able to analyze the
different if used the different diameter.
5 The students should use the industry CNC milling machine used in nowadays to
compare the final product CNC milling machine that used in workshop.
6 The compare different result, the design of the work piece should be varied.

12.0 REFERENCES
1. Mikell P Groover, Principles of Modern Manufacturing, SI Version, 4th Edition, John
Wiley & Son, Inc, 2011
2. Serope Kalpakjian, Manufacturing Engineering and Technology, 10th Edition, Illinois
Institute of Technology, Prentice Hall, 2010
3. P N Rao, Manufacturing Technology, Metal Cutting and Machine Toosl, Universiti
Teknology Mara, Malaysia, Tata Mc Graw Hill, 2000.
4. John A. Schey, J.A., "Introduction To Manufacturing Processes", 5th Edition,
McGraw-Hill, 2000.

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