Report on Training on CNC programming

Turning Center & Machining Center

28-30 July 2011 and 11-13 Aug 2011 Bangalore, UNIDO ICAMT
Technology Development and Productivity Enhancement of Machine Tools Industry within the framework of UNIDOs International Centre for Advancement of Manufacturing Technology (ICAMT)

by Mr. Kashinath M. Patnasetty National Consultant, UNIDO ICAMT

CONTENTS

Agenda (28-30 July 2011) Agenda (11-13 Aug 2011) Introduction Objectives Training Method Benefits to Participants Conclusions and Recommendations List of participants Feedback Forms

3 5 7 8 9 10 11 12

Agenda
Workshop on Turning Center Machining Technology

Turning Centre, CAD/CAM

28-30 July 2011
Time
0900 0930 Hours 930 1000 Hours 1000am 1100 Hours 1100 1115 Hours 1115 1300 Hours 1300 1345 Hours 1345 1500 Hours

Agenda
Registration Welcome Address Knowledge inventory Knowing participants skill on CNC machining Coffee/Tea Introduction : Turning Centers and Applications

28th July 2011

Lunch Turning Operations and techniques Cutting tools and its applications Insert holder selection ISO nomenclature Insert/Holder Coffee/tea Cutting parameters & Calculations Introduction to G & M codes

1500 1515 Hours 1515 1630 Hours 1630 1700 Hours

Q & A /Homework

29th July 2011

0930 1100 Hours 1100 1115 Hours 1115 1300 Hours 1300 1345 Hours 1345 1500 Hours 1500 1515 Hours 1515 1730 Hours G-code M-code functions and program formats Coffee/Tea Part Program practice Canned Cycles Lunch Part Program practice Sub program Coffee/Tea

CADEM CAD/CAM CAPSturn Practice

30th July 2011

0930 1230 Hours 1300 1345 Hours 1345 1500 Hours 1500 1515Hours 1515 1615 Hours 1615 1730 Hours Machine shop visit for DEMO and hands-on Lunch Exercise Tool selection / Part programming Coffee/Tea Safety and productivity Q & A / Valedictory

Agenda
Workshop on Machining Center Machining Technology

Machining Centre (VMC HMC), CAD/CAM 11-13 August 2011 Time

0900 0930 Hours 930 1000 Hours 1000am 1100 Hours 1100 1115 Hours 1115 1300 Hours 1300 1345 Hours 1345 1500 Hours

Agenda
Registration Welcome Address Knowledge inventory Knowing participants skill on CNC machining Coffee/Tea Introduction : Machining Centres and Applications Lunch Milling Operations and techniques Cutting tools and its applications Insert holder selection ISO nomenclature Insert/Holder Coffee/tea Cutting parameters & Calculations Introduction to G & M codes

11th August 2011

1500 1515 Hours 1515 1630 Hours 1630 1700 Hours

Q & A /Homework

12th August 2011

0930 1100 Hours 1100 1115 Hours 1115 1300 Hours 1300 1345 Hours 1345 1500 Hours 1500 1515 Hours 1515 1730 Hours G-code M-code functions and program formats Coffee/Tea Part Program practice Canned Cycles Lunch Part Program practice Sub program Coffee/Tea

CADEM CAD/CAM CAPSmill Practice

13th August 2011

0930 1230 Hours 1300 1345 Hours 1345 1500 Hours 1500 1515Hours 1515 1615 Hours 1615 1730 Hours Machine shop visit for DEMO and hands-on Lunch Exercise Tool selection / Part programming Coffee/Tea Safety and productivity Q & A / Valedictory

Introduction

Three day Training on turning centers machining technology and machining centers machining technology for participants from the Machine Tools Cluster of Bengaluru was conducted at UNIDO International Centre for Advancement of Manufacturing Technology (ICAMT) Headquarters, Bengaluru on 28-30 July and 1113 Aug 2011 (9.30am to 5.30pm). This programme was conducted on specific needs from different machine tool companies belonging to the small and medium sector to improve quality and reduce cost per part machined for assembling the machines.

First 3 day session started on 28th July 2011 9:30 a.m. and concluded on 30th July 2011 at 5:00 p.m. and second session started on 11th Aug 2011 and concluded on 13th Aug 2011. At the outset, Mr. M.S. Dhakad shared the UNIDO initiative to launch the programme on Technology Upgradation and Productivity Enhancement for SMEs. (TUPE) and other initiatives including Advanced Skill Development Programmes, Machine Tools Design School, Programmes on Quality Tools and Technology etc. He emphasized that UNIDO-ICAMT planned to provide more value adding training courses to machine tool industries to increase their skills and enhance productivity.

Objective The objective of the programme was to enhance the skill and productivity of the participants who had prior experience on the shop floor but had not received any formal training or knowledge in the field. This is often a major concern for many small and medium enterprises which lack the resources to invest in training their manpower. This programme aimed to provide them the knowledge and practical hands on experience in a methodical manner that once understood would improve their efficiency by reducing cycle time and programming time, minimize time taken to respond to job quotations and eventually enhance competitiveness and profits for the firms. Specifically the objective of the training was to provide a foundation of knowledge on CNC machining, CAD/CAM, tooling, cutting parameters, process planning, CNC part programming, machine setting, work holding and troubleshooting with emphasis on techniques of efficient metal cutting and best shop floor practices.

Training Method

The training was broken into classroom lecture sessions, simulating and learning through the CAM software and the actual hands-on working on the machines conducted within the IMTMA Bangalore Productivity Centre. The classroom lectures were supported by multimedia presentation and study of live exhibits of cutting tools. The classroom sessions were made highly interactive with frequent question and answer sessions. Machining strategy sessions on live parts was taught by using the software which was followed by group exercises and problem solving to ensure their understanding. For the hands on session the participants were taken to the IMTMA Productivity Centre where they got to work on actual machines and also get some guidance from the operator.

Benefits:

Benefits to Machine tool industries

1. 2. 3. 4. 5. 6. Improved tool life Improve machine life Reduce down time Reduced cycle time Improved productivity Reduced cost per part 1. 2. 3. 4. 5.

Benefits to participants
Multi skill Awareness on resource utilization like CAD/CAM Improved basic knowledge on machining technology Tool selection and troubleshooting techniques Good programming practice

The benefits received by participants as stated in the feedback forms include understanding the importance of planning in advance before execution of any programme. This would avoid any time wastage and would lead to efficient utilization of resources. It also gave them a thorough understanding of the steps involved in turning and milling programming. Also they learnt how to organize their daily work and make the most of their availability on the shop floor. Most of all, the programme encouraged them to add value to their positions at work by bringing about massive reductions in cycle time, improving productivity and enhancing profits for their organisations.

Conclusions and Recommendations 10

The participants showed keen interest and were highly participative and interactive. The list of participants and their feedback is attached. The participants actively participated in the sessions, presenting the problems they had been encountering in the area of CNC machining. However as expressed in the feedback forms the participants made certain suggestions which could further improve such programmes and make them more effective.They suggested training on specific content, larger numbers of participants, more follow up trainings and trainings of a longer duration. Also they expressed their interest in learning other value added topics like cycle time calculation, proposal preparation for the new part development, ISO and special tool selection methods. I am of the opinion that ICAMT need to organize more value added training sessions which will enhance the productivity of their in-house production and their customer part development.

Requirements of Machine tool industries on CNC machining technology: Onsite training

Multi skill development Process plan Tooling Fixturing Cycle time calculation Effective utilization of resources CAD/CAM Developing training modules for their customers

11

List of Participants: 28-30 July 2011

Sr. No.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Name of Person
Mr.Chakravarthy. Mr. Dhanush.Y Mr.Harish Madival Mr. Sathish Kumar Mr. Selvam Mr. Honna Mr. Abhijith C S Mr. Shivaraj Mr. Sandeep Biradar Mr. Hegde

Unit
Dynatech tools and devices Dynatech tools and devices Dynatech tools and devices Growell CNC system Square Engineering works Trishul Machine Tools Pvt. Ltd Trishul Machine Tools Pvt. Ltd Sunrise Technologies Sunrise Technologies Sunrise Technologies

Designation
CNC programmer CNC programmer CNC programmer NEW Product Development Process planner NEW Product Development NEW Product Development Shop Supervisor NEW Product Development NEW Product Development

Email address

dynatech@airtelmail.in

info@growellcnc.com
Prashant_puthrava@yahoo.co.in

shiva@trishulmachine.com

ramesh@sunrisegrp.com

List of Participants: 11-13 Aug 2011

Sr. No.
1. 2. 3. 4. 5. 6. 7. 8. 9.

Name of Person Mr. Krishne Gowda.M.D

Mr. Dhanush.Y Mr. Satish Kumar Mr. Selvam Mr. Honna Mr. Abhijith C S Mr. Shivaraj Mr. Sandeep Biradar Mr. Hegde

Unit
Dynatech tools and devices Dynatech tools and devices Growell CNC system Square Engineering works Trishul Machine Tools Pvt. Ltd Trishul Machine Tools Pvt. Ltd Sunrise Technologies Sunrise Technologies Sunrise Technologies

Designation
CNC programmer

Email address

dynatech@airtelmail.in CNC programmer CNC setter and Trainer Process planner New Product Development New Product Development Shop Supervisor New Product Development New Product Development ramesh@sunrisegrp.com info@growellcnc.com Prashant_puthrava@yaho o.co.in shiva@trishulmachine.com

12