1.

0 TITLE: CNC MILLING

2.0 OBJECTIVES
i. To understand more on about development and the principle of CNC machine.
ii. To gain more understanding on the fundamentals of NC Code.
iii. To produce a product by using CNC machinery.

3.0 INTRODUCTION

Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) are one of

manufacturing support applications. Computer manufacturing able to deal essentially with
the preparations before actual manufacturing also post-manufacturing operations. While
Computer Numerical Control (CNC) is that the computer transferred the design in CAM
into numbers. This numbers is the coordinates of the graph and to control the movement
of the cutter.

CAD is abbreviations for Computer Aided Design where computer method was used in
order to develop geometric of the product in 3D form. From this 3D form, any
manufacturing and geometric requirements may be examined in order to aid or enhance
the product design that were produce for conceptualization to demonstration.

While CAM is Computer Aided Manufacturing where the use of computer technology in
manufacturing planning and also the control of CNC machine before it conducted. CAM
also helps in simulate the process first. This will reduce the cost as any error during the
process can be avoided.

X, Y and Z coordinates in CAM is really important. It can denote as height, width and
depth. For machinery, these coordinates will be given different values or meanings. The
axis works as coordinate and controls the movement of cutter and enables the materials to
be machined in three directions. Axis references is very critical in order to understand the
information that is being conveyed. It is like a key for a secret language that only certain
knows it and be able to interpret the message. When in horizontal plane, the positive and
negative position of the machine is qualified by the point of view and its references axis.
It is necessary to know which plane and position of its reference before able to utilized
the correct information and take actions. In correct diagnoses of axis and references axis
can results in incorrect diagnoses and unclear communication of the design.
4.0 APPARATUS
i. Computer
ii. CATIA V5
iii. CNC Milling
iv. Cutting Tool

5.0 SAFETY AND EXPERIMENTAL PROCEDURE

5.1 Safety
CNC machineries are generally safe, but there are still lots safety procedures before,
when and after using the machinery. Based on OSHA regulatory, “any machine part,
function, or process that may cause injury must be safeguarded”. This safety
regulatory must be followed and practice when in the laboratory.
a. Before operating the CNC machine;
i. Make sure the safety devices on the CNC machines are firmly fitted in its
place all the times.
ii. Machine must be not in operation during loading.
iii. Make sure any debris from previous operation had been spot-cleaned.
iv. Carefully visually inspect all the moving part and all surfaces.
v. Check the spindle direction and make sure it is in correct direction.
vi. Make sure the tools are free from cracks, sharp and always test the tools first
before operate new session.
b. During Operating;

During the machining process, there are only a few precautions that the operator must
be followed. First make sure the machine door to completely closed before start cycle.
This protective door is really important because it can protect the operator from any
flying sharp chips that were build up during the machining process. After that, when
the machine is in operation, any personnel must stand clear from the machine.

c. After operating (End of the machining process);

i. Make sure the machine is at the end of its cycle and fully stopped.
ii. Remove the parts carefully. Before removing, make sure the product in a
condition that can be handle without any harm and injuries. This is because
 during milling process the temperature of the product increases and can cause
burns.
iii. Spot clean inside of the machine for any debris.
iv. Inspect the tools for any dulling or damage that incurred during previous
process.
v. Make sure the CNC machine shut down completely and properly.
d. General Safety;
i. All personnel must wear the required PPE before entering the laboratory and
operating the machinery. PPE such as, safety glasses, safety boots and proper
attire (workshop jacket). Any loose clothes are prohibited from entering the
lab.
ii. If the personnel have long hair, its is necessary to tie and wear head cover.
iii. Never wear any jewelry when operating machinery.
iv. Do not leave the machine unattended when its running. Make sure its
completely powered down before leave.

5.2 Procedure
5.2.1 NC Code Generation
i. A part with width of 100m, height of 75mm and thickness of 25mm had
been created in CATIA.
ii. Student ID had been pocketed with depth of 1mm by using pocket
operation on the top surface of the part.
iii. Rough stock of the part had been created in order to use machining
function in CATIA.
iv. Milling process was set up and created on the rough stocks. The maximum
cut depth had been set up to 0.1mm.
v. The tool path replay or simulation had been viewed and no error were
found.
vi. NC Code had been generated.
vii. Some editing had been done on the MPF file in order to make it
compatible for CNC machine that will be use.
 a) b)

Figure 1:a) First 15 lines. b) Last 15 lines of generated NC Code.

5.2.2 Milling Process
i. The CNC machine was prepared by following the required step before
conducting machining.
ii. G54 of the machine had been set up in position of x=0 , y=0 and z=0.
iii. Controller of the machined had been loaded with the generated NC Code.
iv. Work piece had been set in its position and the door is closed.
v. The cycle started and the machining processed is began.

6.0 CONCLUSION
As a conclusion, this experiment was successful because all of the objectives were all
achieved completely. In this lab, the basic of NC Code was described completely by the
lecturer although face-to-face lab session cannot be done. Before generating NC Code, a
part must be first produced by using help of CAD application such as CATIA. When all
of the step in the CAD were done NC Code can be generated. Lots of things need to be
checked first before generating NC Code. For an example, the and the type of the cutting
must be correctly chosen. After that, the simulation for the tool path must be previewed
in order to avoid any error when machining process began. When satisfied, the code was
executed. Before transferring it into CNC Machine, slight modification must be done
because the machine that will be use in the laboratory is Siemens 840D while the code is
for Siemens 840. This is important because it is necessary to make the code compatible
for the machine to be interpret. Even though, the machining process in this laboratory is
not real, but it is crucial to know the safety regulation when to operate the CNC Machine.
 From the NC Code generated, every code that were generated and displayed got its own
meaning. Such an example from the first 15 lines of the codes, some code was removed
because the machine unable to execute the process and it may display as errors. On the
first block, G80, G94, G64 and G49 were removed. On block 4, T1 shows that the first
tool that will be used and the tool diameter is 1mm, flat end mill type. During block 5, the
spindle will rapidly travel to datum position and S1000 shows that the spindle speed is
1000rpm. While on block 6, there is no G-codes as it will follow the previous commands
that is rapid travels or positioning to safety plane. For last 15 lines of the NC-code, on
block 73619, the spindle will rapidly travel, ejects from workpiece to high on 20mm from
the workpiece. After that, next block the spindle will stop and the programs will end at
block 73621. While on the next block is optional stop and the last block will move the
cursor to return to Block 1. If want to make second same products, just replace the current
workpiece with new workpieces, set the datum to the same coordinates and on the
machine to start again the process.

7.0 RECOMMENDATION

i. Use flood coolant on the raw material during machining process. This is because
during the milling process, the temperature of the raw material and the tools
increases. This will make the cutting tool life-span shortens.
ii. Increase the maximum cut depth of the machine. the maximum cut depth of the
tool can be increase to shortens the machining process. But it is important that the
maximum cut depth does not exceed the suggested value as the tool can fail if
subjected to immersive load.
iii. Use various spindle rotation speed. For an example, during the roughing process,
slow spindle rotation is enough to create the initial shape that is required and
increase the feed. When entering finishing process, increase the spindle rotation so
it can make a smoother surface. This will save lots of time rather than only using
single spindle rotation speed.