‘SUMMER TRAINING REPORT’

“IN”
ORDNANCE FACTORY
MURADNAGAR
“ON”

COMPUTER NUMERICAL
CONTROL

SUBMITTED TO:
THE GENERAL MANAGAR,ORDNANCE
FACTORY MURANAGAR..
SUBMITTED BY:

EC(2ND YEAR,B.TECH)
COMPUTER NUMERCAL
CONTROL

CNC

Computer Numerical Control is the control of a machine tool using numbers and letters.
It is a system in which programmed numerical values are directly inserted and stored on
some form of input medium, and automatically read and decoded to cause a
corresponding movement in the machine which it is controlling.

Advantages of CNC

 High degree of quality due to accuracy, repeatability, and freedom from operator-
introduced variations.

 Reduced scrap. Errors due to operator fatigue, interruptions, and other factors are less
likely to occur.

 Simplified inspection. Once the first piece has passed inspection, minimal inspection is
required on subsequent parts

 Lower tooling costs due to less need for complex jigs and fixtures.

 Reduced lead time.

 Complex machining operations are more easily accomplished due to advanced machine
control.
 CNC Disadvantages

 Tools on NC machines do not cut metal any faster than conventional machines.

 NC does not eliminate the need for expensive tools. There is also a greater initial cost
involved with the NC machine.

 NC will not totally eliminate errors. Operators can still fail to push the correct buttons,
make incorrect alignments, and fail to locate parts properly in a fixture.

 Selection and training of programmers and maintenance personnel is required.

CNC History

 1947 - John Parsons began experimenting with the idea of generating thru-axis curve data
and using that data to control machine tool motions.

 1949 - A contract was granted to the Parsons Corporation to search for a speedy
production method.

 1952 - MIT successfully demonstrates a model of the NC machine of today. The machine
successfully made parts with simultaneous thru-axis cutting tool movements. MIT coined
the term "numerical control".

 1955 - Commercial models of NC machines displayed for customer acceptance.

 1957 - NC accepted by industry; several are installed and in use.

 Prerequisites

 Blueprint Reading

 Workpiece and Fixture setup

 Familiarity with machine operations - machine tools, cutting speeds, feed rates, and depth
of cut.

 Familiarity with the machine being programmed; its general operating characteristics;
tape, floppy, or network data input; and the machine's control panel operation.

 Understanding of basic computer operations, CNC programming, and data translations.

CNC EQUIPMENT

Milling Machines

CNC Milling Machines use a rotary cutter for cutter motion and linear motion for feed.
The material is pushed into the cutter, or the cutter is pushed into the material, in 3
dimensional straight or curved paths to produce the desired part elements. The finished
part is created by removing all unnecessary material from the workpiece. This process is
called Milling.
 Lathes

CNC Lathes rotate the work against a single point tool to produce cutting motion. The
tool is fed along or into the work to produce the feed motion. Machining a part on a lathe
is called Turning.

Machining Centers

Machining Centers are more sophisticated CNC machines that often combine milling and
turning technologies.
 EDM Machines

An Electrical Discharge Machine uses electric sparks to make a cavity in a piece of

metal. This process requires an electrode, a power source, a tank, and coolant. The
workpiece is connected to one side of the power supply and placed in the tank. The
electrode, which is made in the shape of the cavity that is desired, is connected to the
other side of the power supply. The tank is filled with coolant. This coolant is a dielectric
material. A dielectric resists the flow of electricity. The electrode is lowered until a spark
jumps between the electrode and the work. When the spark jumps, the dielectric quality
of the coolant has been overcome. The spark dislodges small particles of material that are
carried away by the coolant. A cavity of the same shape as the electrode is created. The
electrode is lowered as the cavity is produced until the proper depth is achieved.
ROBOTS
 Industrial Robots are specialized machine tools that are a direct replacement for human
labor. I/Rs are used to consistently perform tasks that are monotonous, repetitive, and/or
hazardous. Some examples are; welding, spray painting, soldering, paletizing, transfer of
materials, and tool and part changers for CNC machines.

CNC Control Panels

CNC Control panels include the controls for all aspects of the machining process. Some
machines also include part programming and tool path verification.

CNC Systems

 Point-to-point control is the positioning of the tool from one point to another within a
coordinate system. Most often used for positioning to a point where a manual machining
operation such as drilling or boring would occur.

 Straight-cut control has the ability move a tool, while engaged, straight in all axes of the
machine and has the ability to do angles of 45 degrees.
 Contouring control systems generate a continuously controlled toolpath by interpolating
intermediate points or coordinates. Interpolating means the ability to generate the points
that make up a path.

MACHINE TOOL PRACTICES

Design and setup of Fixtures

A fixture is a production tool that locates, holds, and supports the workpiece securely so
that the machining operations can be performed exactly the same for duplicate parts (ie.
production runs). Although largely used on milling machines, fixtures are also designed
to work for various operations on most of the standard machine tools. Fixtures vary in
design from relatively simple tools to expensive, complicated devices.

 Plate fixtures are the simplest basic fixture made from a flat plate which has a
variety of clamps, locators, or pins to hold and locate a part. Its simplicity and
adaptability make it a popular type of fixture.
 Angle-plate fixtures are a variation of the plate fixture that is used to machine the
part at a right angle to its locator point. Most angle-plate fixtures are made at 90
degrees but they can be made at other angles.
 Vise-jaw fixtures are for machining small parts. With this type of fixture the
standard vise jaws are replaced with jaws that are formed to fit the part. These
fixtures are the least expensive type of fixtures to make and their use is only
limited by the sizes of vises available.
  Indexing fixtures are used for maching parts which must have machined details
evenly spaced.
 Multistation fixtures are used primarily for high-speed, high- volume production
runs where the machining cycle must be continuous.
 Duplex fixtures are the simplest form of multistation fixtures. This fixture allows
for the loading and unloading operations to be performed while the machining
operations are in progress. Thus allowing non-stop machining.
 Profiling fixtures are used to guide tools for machining contours which the
machine cannot normally follow. CNC Machines do not use these types of
fixtures.

Some production operations that use fixtures:

 Assembling
 Boring
 Broaching
 Drilling
 Forming
 Gauging
 Grinding
 Heat Treating
 Honing
 Inspecting
 Lapping
 Milling
 Planing
 Polishing
 Punching
 Reaming
 Sawing
 Shaping
 Stamping
 Tapping
 Testing
 Turning
 Welding

Various Geometry Producing Tools

A Milling machine boring bar and Lathe tools

Endmills and Drill, Ream, Tap, Grinding wheel and bits

Climb and Conventional Milling

Climb milling or down-milling is when the work is moved in the same direction as the
rotation of the cutter. Full engagement of the tooth is instantaneous. The sliding action of
conventional milling is eliminated resulting in a better surface finish and longer tool life.
Conventional or up-milling is when the work is fed into the rotation of the cutter. The
chips are at a minimun thickness at the start of the cut and are so light that the tool has a
tendency to slide over the work. This sliding, followed by a sudden breakthrough as the
tool completes the cut, causes a rough surface finish.

Cutting Data and Formulas

Here are some of the most common terms used for expressing cutting data:

 Spindle speed - Spindle speed is the rotational speed of the spindle and tooling. This
value is usually expressed in RPM. (Revolutions Per Minute)

 Feedrate value - The feedrate value is the numerical value at which a tool will
traverse a workpiece. It is usually expressed in either IPM (Inches Per Minute) or IPR
(Inches Per Revolution).

 Cutting speed - Cutting speed is the rotational speed of the cutting tool or workpiece.
It can be stated as either RPM or SFM. (Surface Feet Per Minute)

 Depth of Cut - Depth of cut is the distance the tool tip is engaged into the workpiece.
It is incorporated into the X, Y, and Z values in a CNC program. Separate from the
program, it can be expressed in inches or mm.

Calculating the cutting data is an important step in the planning of a CNC program.
Several of the most common formulas are explained here.

 S.F.M = R.P.M. x Diameter x .262

Example: Find the Surface Feet per Minute of a 1" tool at 600 RPM
SFM = RPM x 1 x .262
SFM = 600 x 1 x .262
SFM = 157.2

 R.P.M. = S.F.M. x 3.82 / Diameter

Example: Find the RPM of a 1" tool at 150 SFM.
RPM = SFM x 3.82 / Diameter
RPM = 150 x 3.82 / 1
RPM = 573