Rough Turning on CNC

1. Problem Definition: To determine the;

i. Designation of various tools used for the machining of Aluminium
workpieces/components on CNC machine tool.
ii. Understanding various cutting conditions during the machining.
iii. Determining the grades of various tool inserts used for rough
turning operations.
iv. Checking the specifications of the respective machine tool.
v. Checking the surface roughness values for the rough turning
operation on CNC machine.

2. Name of industry visited and address:

KRISHNA INDUSTRIES
W7, Gokul Shirgoan, M.I.D.C.,
Kolhapur- 416 234 Maharashtra (India)
Phone: +91231-6516297 Tele Fax: +91231-2672799
Email: ki@krishnagroup.ind.in

3. Operation: Rough Turning

Rough Turning is the process of removal of excess material from the
workpiece in a minimum time by applying high rate of feed and heavy depth of
cut. The roughing cut should be so made that the machine should bear the load.
The difference between the rough turning and finish turning is that rough turning
is done to achieve the ideal size of the workpiece. While the finish turning is done
to smoothen the workpiece.
 Name of the component: Water Jacket
Dimensions Dimensions Dimension Dimensions
of Casting achieved after achieved after
rough turning finish turning
ID: 212mm 220mm 222mm
OD: 248mm 240mm 238mm
Length: 158mm - 156mm

4. Material of Component/Workpiece:
Al 53000
Aluminium alloy
Al 6063

5. Quality Check:
The achieved surface finish for ID, OD and other surfaces is
0.6Ra as per requirement.
The dimensions of ID and OD are within the tolerance of
+/- 0.1mm.

6. Cutting Conditions: The cutting conditions which are considered while

machining on CNC machine tool are Speed, Feed and Depth of Cut.
Cutting conditions Rough turning Finish turning
Spindle speed RPM 400 450
Feed rate mm/rev. 0.1 to 0.8 0.1 to 0.15
Depth of cut mm 2mm 0.5mm

Coolant used for both the operations:

Spectrum. Grade 6 to 10%
7. Specifications of machine tool:
CNC machine tool
Model: DX 200 Sr. No. 60010774-2014
Manufacturer: Jyoti
Input voltage: 415±05% V
Input frequency: 50 Hz
Input power: 20 Kw
Machine weight: 3800(APPX) Kg

8. Cutting Inserts/Tool:

There are two different types of inserts used for rough turning and finish
turning. 0.8 nose radius insert is used for rough turning operation and 0.4
nose radius insert is used for finish turning.

Manufacturer: KORLOY, SANDVICK.

Insert range: 2mm to 8mm

Name of insert: CNMG120408-HM

Specification: CNMG432

Grade: PC9030

9. Tool Holder: