ISLAMIC UNIVERSITY OF TECHNOLOGY8

DEPT. OF MECHANICAL & CHEMICAL ENGINEERING

MCE 4628

Machine tools lab

Exp. Number: 08

Exp. Name:

STUDY OF A CNC LATHE MACHINE

Date of Submission: 16.10.2017 Prepared by,

Md. Kabbir Hossain

141437

MCE14
OBJECTIVE
To learn how to fully use a CNC LATHE machine, from understanding how to design the work
piece to learning how to safely operate the machinery and its many functions, such as drilling,
roughing, facing and threading.

INTRODUCTION

In order to meet the increasing demand to manufacture complicated components of high accuracy
in large quantities, sophisticated technological equipment and machinery have been developed.
Production of these components calls for machine tools which can be set up fairly rapidly without
much attention.

The design and construction of Computer Numerically Controlled (CNC) machines differs greatly
from that of conventional machine tools. This difference arises from the requirements of higher
performance levels. The CNC machines often employ the various mechatronics elements that
have been developed over the years. However, the quality and reliability of these machines
depends on the various machine elements and subsystems of the machines. There are some of
the important constituents parts and aspects of CNC machines to be considered in their
designing, for example Machine structure, Guideways, Feed drives, Spindle and Spindle
bearings, Measuring systems, Controls, Software and Operator interface, Gauging, Tool
monitoring.

The control of a machine tool by means of stored information through the computer is known as
Computer Numerically Controlled. The information stored in the computer can be read by
automatic means and converted into electrical signals, which operate the electrically controlled
servo systems. Electrically controlled servo systems permits the slides of a machine tool to be
driven simultaneously and at the apporopriate feeds and direction so that complex shapes can be
cut, often with a single operation and without the need to reorient the workpiece.

Computer Numerically Control can be applied to milling machines, Lathe machines, Grinding
machines, Boring machines, Flame cutters, Drilling machines etc.

FEATURES OF CNC MACHINES

Rigid machine structure is provided, in order to bear the static load, Dynamic load ,
Thermal load , Vibration.
Guideways are used in machine tools to control the direction or line of action of the
carriage or the table on which a tool or workpiece is held , To absorb all the static and
dynamic forces.
On a CNC machine the function of feed rate drive is to provide motion to the slide as per
the motion commands. Since the degree of accuracy requirements are high, the feed
drive should having high efficiency and response.
Hydrodynamic bearings, Hydrostatic Bearings, Antifriction Bearings are provided to the
CNC machine. In order to achieve the accuracy and the quality of the work produced
 depends directly on the geometrical accuracy, running accuracy and the stiffness of the
spindle assembly.
On all CNC machines, an electronic measuring system is employed on each controlled
axis to monitor the movement and to compare the position of the slide and the spindle
with the desired position.
CNC controls are the heart of the CNC machines. The early CNC controls were developed
for simple applications in turning, machining centres and grinding. But with increased
capabilities on modern machine tools such as higher spindle speeds, higher rapid
traverses and more number of axes, CNC systems have been developed to meet these
needs.
Better work piece quality is one of the most important advantages in using a hi-tech CNC
machine. To maintain quality the effect of parameters like tool wear and thermal growth
can be eliminated by automatic gauging system.
Presently, established tool monitoring sensors and systems are available commercially
for integrating and systems are available commercially for integrating with CNC
machines. Tool monitoring systems enable the introduction of adaptive controls on
machines for optimizing the cutting parameters.
Feedback is taken from various devices, e.g. Ecoders, Transducers.

CONFIGURATION OF CNC SYSTEM

Fig shows a schematic diagram of the working principle of an NC axis of a CNC machine
and the interface of a CNC control.

A CNC system basically consists of the following:-

Central processing unit (CPU).

Servo control unit
Operator control panel
Machine control panel
Other peripheral devices
Programmable logic controller
Figure gives the typical control configuration of Hinumerik 3100 CNC system.
PROGRAMMING FOR CNC MACHINES

A program is a set of encoded information giving coordinate values and other details to indicate
how a tool should be moved in relation to a work piece in order to achieve a desired machining
form. A part program contains all the information for the machining of a component which is
input to CNC system. The CNC system provides signals at the correct time and in the correct
sequence to the various drive units of the machine.

PROCEDURE OF PART PROGRAMMING

1) Study the relevant component drawing thoroughly.

2) Identify the type of material to be machined.
3) Determine the specifications and functions of machine to be used.
4) Decide the dimension and mode i.e. Metric or inch.
5) Decide the co ordinate system i.e. Absolute or incremental
6) Identify the plane of cutting.
7) Determine the cutting parameters for the job / tool combination.
8) Decide the feed rate programming.
9) Check the tooling required.
10) Establish the sequence of machining operations.
11) Identify whether use of special features like subroutines, mirror imaging etc. is
required or not.
12) Decide the mode of storing the part program once it is completed.

STRUCTURE OF A PART PROGRAMMING

Part program defines a sequence of NC machining operations. The information

contained in the program can be dimensional or non dimensional like speed, feed, auxiliary
functions, etc.. The basic unit of a part program input to the control is called a block. Each block
contains adequate information for the machine to perform a movement and or functions. Block
in turn are made up of words and each word consists of a number of characters. All blocks are
terminated by the block end character. The maximum block length for each CNC is fixed. A
block may contain any or all the following :-

Optional block skip ( / ).

Sequence or block number (N).
Preparatory functions (G).
Dimensional information ( X,Y,Z etc. )
Decimal point (.).
Feed rate (F).
Spindle speed (S).
Tool number (T).
Tool offset function (D).
Miscellaneous functions (M,H, etc. )
End of block (EOB / *)
BLOCK EXAMPLE

N 1234 G..X..Y..S..M..F..T..D..EOB.

Where ,

N ...= Address of block number.

1234. = Block number.

G ..= Preparatory function.

XY= Transient information.

S...= Spindle speed function.

M.= Miscellaneous function.

F..=Feed function.

T..=Tool function.

D..= Compensation function.

EOB =End of Block.

Designation of some letters for certain addresses had been standardized, for e.g. The letter N
always designates block number, other letters in standardized list are
P,G,M,X,Y,Z,I,J,K,L,U,V,W,A,B,C,F,S,T,EOB. A CNC manufacturer may use some letters which
are not standardized for special words, e.g. R and H used in controls manufactured by Fanuc or
Siemens.

CNC LATHE MACHINE:

A lathe is a machine tool which rotates the work piece on its axis to perform various operations
such as cutting, sanding, knurling, drilling, or deformation with tools that are applied to the work
piece to create an object which has symmetry about an axis of rotation.

Computer numerical controlled (CNC) lathes are rapidly replacing the older production lathes
due to their ease of setting, operation, repeatability and accuracy. The part may be designed
and the tool paths programmed by the CAD/CAM process or manually by the programmer, and
the resulting file uploaded to the machine, and once set and trialed the machine will continue to
turn out parts under the occasional supervision of an operator. The machine is controlled
electronically via a computer menu style interface, thus the program may be modified and
displayed at the machine, along with a simulated view of the process.
Safety:
Due to the nature of its operations, the machine produces sharp shards as leftovers of cut
material, thus making it necessary for the operator to wear protection gloves (1) while
fixing/moving the work piece and/or tools. With this specific CNC machine, safety goggles
werent necessary as the machine has a protection screen that completely covers the
workspace while it is operated. It is important to note that the use of safety goggles is
compulsory otherwise. The use of a lab coat is usually recommended with machines that might
propel liquids and shards out, however this was not the case. It is important to note that the use
of closed shoes (2) is mandatory for those entering the lab. The CNC Lathe machine has an
Emergency stop button (3) in case any unforeseen dangerous situation/mechanical failure
occurs.
(1) (2)

(3)

Raw materials and Tools:

Our piece was manufactured on a solid Aluminum cylinder of thickness 19.7mm and
unimportant length (4). The tools (drilling/cutting) were already fixed onto the machine (5). A
digital Vernier caliper (6) was used to take measurements.
(4) (5)

(6)

Uses of a Lathe machine:

A Lathe can be used for manufacturing any cylindrical piece, no matter how much detail goes
into it as long as the piece is symmetrical to the spinning axis of the lath

Examples:
How to operate the CNC Lathe:
Having the design in hand, the first step is to open the machines software (Boxford v10
CAD/CAM) and select the correct machine (in this case, Lathe (160TCL)-Serial #9318). After
that, the machines menu will be presented and at this stage, we used the CAD NEW option (as
we have yet to learn G code) to reproduce the design. The first step is to enter details such as
creator and primary dimensions (out dimension; inside dimensions; length; hole depth). When
that is done, a 2D grid is produced, in which the operator will draw the piece to be cut. After the
shape is done and saved, the operator should launch a 3D render application, which will give
the final looks of the work piece. After that, go to File>Process Billet to insert parameters such
as Material and dimensions. The software will then give the operator a simulation of the work
process and look for possible erros and failures. If the design passes, the operator will be able
to click the machine icon, leading to the final manufacturing of the piece. When that is done, the
software will ask you to follow some steps: Cancer manual mode; press Auto Home; enter
current turret position (written behind the tool which is currently in use); fit the work piece into
chuck; press cycle start. Now the machine will start to manufacture the piece and a real time
simulation will be shown onscreen. At this point, the operator should supervise the machine in
case of unforeseen scenarios such as mechanical failure. After some minutes, the final work
piece (7) will be ready.
ADVANTAGES

Higher flexibility.
Increased productivity.
Consistent quality.
Reduced scrap rate.
Reliable operation.
Reduced non-productive time.
Reduced manpower.
Shorter cycle time.
Just in time manufacture.
An automatic material handling.
Lesser floor space.
Increased operational safety.
Machining of advanced materials.

DISADVANTAGES

CNC machines are more expensive than manually operated machines.

Investment in CNC machines can lead to unemployment.
Higher maintenance cost.
Costlier CNC personnel.
Air conditioned place are required for installation of the machines.
Unsuitable for long run applications.
Training of part programmer is required.