Module 1.1
Module 1.1
Module 1.1
INTRODUCTION
September 2023,
ii
MANUFACTURING PROCESS LABORATORY ASSISTANTS 2022/2023
iii
MANUFACTURING Document
PROCESS LABORATORY Number
Form
MODULE 1.1
Number
Valid 2023
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A. Tools and Requirements
Tools & Software Requirements
1. HAAS Control Simulator 1. Labwork of Module 1.1
2. Guideline of Module 1.1
3. Stationary
B. Reference
Autodesk. (2014). Autodesk. From https://www.autodesk.com/
Groover, M. (2020). Fundamentals of Modern Manufacturing: Materials, Processes,
and Systems (7th Edition). Danvers: John Wiley and Sons Inc.
H. Wang, G. C. (n.d.). A Novel Combination of Electrical Discharge Machining and
Electodeposition for Superamphiphobic Metallic Surface Fabrication.
Haas Automation. (2022). Haas F1 Team Official Machine Tool. From Haas
Automation,
Inc – CNC Machine Tools: https://www.haascnc.com/index.html
Harling, V. N. (2020). Comparative Analysis of Speed and Cutting Results of St-37 Soft
Steel.
Thing, J. (2017). Mill Operator's Manual. Oxnard: Haas Autmation, Inc. U.S.A.
v
C. Labwork
Flow Process Chart Process Description
1. Read the study case well. Because it
contained information for finishing
the labwork.
2. Pay attention to detail specification
for each operation.
3. Create NC Code for facing
subprogram on worksheet.
4. Create NC Code for profiling
subprogram on worksheet.
5. Create NC Code for circle mill
subprogram on worksheet.
6. Based on the NC Code subprogram
before, create the NC Code main
program. Create the NC Code for
main program on worksheet.
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MODULE-1.1
MACHINING PROCESS: NC CODE MILLING
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3.1 Overview CNC Milling
3.1.1 CNC Milling
Computer numerical control milling machines are milling machines in
which the cutter path is controlled by alphanumerical data rather than a
physical template. They are especially suited to profile milling, pocket
milling, surface contouring, and die sinking operations, in which two or
three axes of the worktable must be simultaneously controlled to achieve
the required cutter path. An operator is normally required to change cutters
as well as load and unload work parts.
3.1.2 Milling Process
The milling machining process is the process of cutting the workpiece
using a cutting tool with multiple rotating cutting blades. A cutting process
with many cutting teeth surrounding the cool can result in a faster
machining process. The cut surface can be flat, angled, or curved. The
workpiece surface is also a combination of several shapes. (Harling, 2020)
The milling process is a type of machine tool that has its distinctive
features because it can carry out various metal removal processes by
feeding the workpiece with a rotating cutter. Below is the figure for the
milling process.
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3.2 Main Classification of Milling Processes
There are two types of milling operation, peripheral milling and face milling.
Here are some explanations about peripheral milling and face milling operation:
3.2.1 Peripheral Milling
Peripheral milling is also called ordinary milling, the tool axis is parallel to
the surface being machined, and the operation is carried out by cutting the
edge on the outer edge of the cutter. (Groover, 2020)
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Here are the characteristics of face milling:
a. The surface cutting is placed perpendicular to the workpiece.
b. Essentially positioned face down towards the top of the workpiece.
c. Only the tip of the cutter is exposed to the workpiece.
Below are the disadvantages of NC Milling over conventional milling one as follows:
1. NC machines are expensive.
2. Very dependent on electricity.
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3.4 Types of Milling Machines
3.4.1 Based on Machine
The milling machine shall provide a rotating spindle for the cutter and a
table for fastening, positioning, and feeding the work part. Various machine
tool designs can meet these requirements. To begin with, milling machines
can be classified as either horizontal milling machines or vertical milling
machines. The horizontal milling machine has a horizontal spindle, and this
design is especially suitable for performing peripheral milling of cuboidal
work parts. The vertical milling machine has a vertical spindle, and this
orientation is suitable for face milling, finishing milling, surface shaping, and
die sinking on flat work parts (Groover, 2020). Below are two types of
milling machines:
Figure 1.1. 4 (a) Vertical Milling, (b) Horizontal Milling (Haas Automation, 2022)
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3.4.2.1 Up Milling (Conventional)
The motion of the tool rotation is in the opposite direction to the
feeding motion of the milling machine table. For example, in the
milling process it increases if the tool rotates clockwise, the
workpiece is sliced to the right. The cross section of the chips shape
for the upward milling process is like a comma starting with a
minimum thickness then thickens.
3.4.2.2 Down Milling (Climb)
The direction of the tool rotation is the same as the feeding
direction of the milling machine table. For example, if the tool
rotates counterclockwise, the workpiece is sliced to the right. The
cross section of the chips shaped for the upward milling process is like
a comma starting with the maximum thickness then thinning.
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other milling operations.
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Table 1.1. 1 Types of Milling Cutters (Haas Automation, 2022) (cont.)
Reamers are used to
enlarge an existing hole to
a precise tolerance and to
add a high- quality surface
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3.7 Setup
To set up the milling operation, the parts are placed and clamped on the work
holding. There are three types of work holding milling, namely fixture, vice, and
clamp. For those that are placed, the part is placed in the work holding namely
fixture, while for the clamped part, the part can be clamped by two other work
holdings, namely vice and clamp.
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Figure 1.1. 9 Start Point Starting from Right
3.8.2 Program Structure
Some structures must be followed in making code for the milling process.
Startwith the title for the program, the body of the program, and the end of
the program. The milling process on a CNC Machine uses codes that are
integrated into one another. To make it easier for the operator, the milling
process has a sub-calling program which will be called by the main program.
A sub-calling program will help shorten the code used when the machining
process is used more than one. This is due to the written code does not
need the whole program, but only by calling it. The Program structure
consists of several structures of codes to familiarize such as:
Table 1.1. 3 Table of Structure of Program
No. Structure of Program Definition
This is the title of the program. It contains
the number of programs that have been
made by the operator. The title of the
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Table 1.1. 3 Table of Structure of Program
Used to start placing a tool on the
spindle or to change a tool on the spindle
to another.
3. Select Tool TX M06
TX: Number of the tool used (X means tool
number)
M06: Code for tool change.
Used to move the spindle to the X-axis and
Y-axis of the datum.
G00 G90 G54/G55/G56/G57/G58/G59 X…
Y…
Rapid Move toDatum G00: Code for rapid positioning.
4.
Point G90: Absolute positioning command.
G54-G59: Zero offset/Datum for the
program.
*’…’ The blank space based on the
parameter/study case.
Used to activate the spindle. The spindle
will startrotating on an axis in a
clockwise or counterclockwise direction.
5. Spindle On S... M03
S: Spindle speed (‘…’ based on parameter).
M03: Spindle clockwise.
M04: Spindle counterclockwise.
There are several programs used in the
code to define the movement of the
machine such as code for calling the
6. Program subprogram, code for tool height offset
compensation, code for tool compensation
on the right or left side used, and a rapid
move to the starting point to the safety
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movement.
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M98 PXXXXX LX
M98: Subprogram call.
PXXXXX: “P” is used to replace “O” from
the title
program, for change the subprogram into a
program (in the main program).
LX: Looping (X means number of looping)
G43 H0X Z60.
G43: Tool height offset compensation.
H0X: Height tool number (X means tool
number)
Z60: Default safety movement used.
G90 G01 X… Y… F…
G90: Absolute positioning command.
*’…’ The blank space based on
parameter/study
case.
G41/G42 DX
G41: Tool compensation (from right).
G42: Tool compensation (from left).
DX: Compensation for tool diameter (X
means tool number).
G98 G81/G83 Z… R… F…
G98: Canned cycle initial point return.
G81: Drill canned cycle.
G83: Peck drill canned cycle.
R: Retract from surface.
Q: Peck depth (only in G83).
*’…’ The blank space based on
parameter/study case.
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Used to move the tool out from the
workpiece to
the safety zone.
G00 G28 Z60.
G28: Code for return to home position
Z60: Default safety movement used in
Process
7. Safety Movement Manufacturing Laboratory.
G28 G40 Z0.
G40: Tool radius compensation off (cancel
G41 & G42). Bring back the tool to the
center of the toolpath.
G00 G90 G80 Z60.
G80: Cancelation canned cycle (cancel G81,
G83 & G84).
G28 Z0.
8. Homing Tool
G28 X0. Y0.
Spindle Off
9.
M05
Spindle off
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Table 1.1. 3 Table of Structure of Program (cont.)
M30
Program end. This also stops the spindle
and turns off the coolant. The program
pointer will be reset to the first block.
M02
The program ends, but it does not reset to
the next block. This code will hold the
program automatically for the operator,
then it will start to move again if the
operator manually activates the program.
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Figure 1.1. 10 Guide Part
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3.9.2 Create NC Code Milling Program
In this case, you are asked to create NC Code with sub calling program
on the part with known data as follows. Then, make the main program call
all the sub calling program.
Depth of Cut : 2 mm
Material’s Thickness : 20 mm
Tool Number :1
Tool Diameter : 40 mm
Stepover : 50%
Allowance : 1 mm
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FACING SUB PROGRAM
G01 G90 Z-2. F150; Feed movement to Z-2 with feed rate =
150
Notes:
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3.9.2.2 Profiling Operation
Profiling operation is used to define the shape of the part in
milling process and used to rough or finish vertical or slanted
surfaces.
Depth of Cut : 2 mm
Material’s Thickness : 18 mm
Tool Number :2
Tool Diameter : 10 mm
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PROFILING SUB PROGRAM
G01 G91 Z-2. F150; Feed movement to Z-2 with feed rate =
150
Notes:
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3.9.2.3 Circle Mill Operation
Circle mill operation is used to make a big hole in a part.
Depth of Cut : 2 mm
Material’s Thickness : 18 mm
Tool Number :2
Tool Diameter : 10 mm
Start Point :J
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CIRCLE MILL SUB PROGRAM
O10013; Title of Program
Notes:
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3.9.2.4 Center Drill Operation
Center drill is used to make a center hole at the edge of the
surface of the part, it is usually used to give a mark for the next
drill process. This mark will also help so that the tool for the drill
operation will stay on the demanded hole.
Retract : 5 mm
Material’s Thickness : 18 mm
Tool Number :3
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CENTER DRILL SUB PROGRAM
G98 G81 Z-3.5 R5. F60; Center drilling to Z- 3.5 with retract
from surface for 5 and feed rate 60
M99;
Notes:
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3.9.2.5 Peck Drill Operation
Peck drill operation is a process of drilling which is carried out
several times untilit reaches the drill depth point.
Retract : 5 mm
Material’s Thickness : 18 mm
Tool Number :4
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PECK DRILL SUB PROGRAM
G98 G83 Z-23.25 Q5. R5. F60; Peck drilling to Z-23.25, retract from
surface for 5 with pecking 5 times
and feed rate 60
M99;
Notes:
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Main Program
After all the subprogram has been created, we then create the main program
for the Guide Part to call all the subprogram we have made above. Main
program can be seen as below:
M98 P10011 L3; Calling sub program facing and looping for 3
times
for 9 times
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G01 G90 Z0. F140; Rapid move to the starting point
for 9 times
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M30; End of program
Notes:
[2] Blue font is used as the movement of tool that follows the geometry
shape.
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Autodesk. (2014). Autodesk. From https://www.autodesk.com/
Groover, M. (2020). Fundamentals of Modern Manufacturing: Materials, Processes, and
Systems(7th Edition). Danvers: John Wiley and Sons Inc.
H. Wang, G. C. (n.d.). A Novel Combination of Electrical Discharge Machining and
Electodeposition for Superamphiphobic Metallic Surface Fabrication.
Haas Automation. (2022). Haas F1 Team Official Machine Tool. From Haas Automation, Inc –
CNC Machine Tools: https://www.haascnc.com/index.html
Harling, V. N. (2020). Comparative Analysis of Speed and Cutting Results of St-37 Soft Steel.
Thing, J. (2017). Mill Operator's Manual. Oxnard: Haas Automation, Inc. U.S.A.
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