CNC Milling Machine

Encik Adib bin Amin

Prepared for

Mazlin Azura binti Usop

By

TA13019

Section / Group

02 / Group 6

Date

6th October 2015

2.0 Abstract:
This laboratory is to teach us about the CNC usage and explain briefly about the EDU
CIM System. The most basic function of any CNC machine is automatic, precise, and consistent
motion control. A CNC user must understand the makeup of the CNC machine tool being
utilized. The most important thing is to understand the basic machining practice that goes into
using the CNC machine tool. Four basic areas must be concentrated. First, we should understand
the machine's most basic components. Second, we should become comfortable with the
machine's directions of motion (axes). Third, we should become familiar with any accessories

equipped with the machine. And fourth, we should find out what programmable functions are
included with the machine and learn how they are programmed. There are a few important
benefits offered by CNC equipment, where the first one is it has improved automation. Besides,
it is consistent, accurate workpieces and flexible.
The last part is we need to be familiar with the EDU VR1 CIM-110 (EDU CIM System).
Some of the things that we must know are 6-Axis Mitsubishi Robot with the function of Auto
Mode Switching, Auto Storage and Retrieve (ASRS) Station (Material Handling), Vision
Inspection Station (Vision Camera and Computer Station), and the most important one, CIM
System with SCADA Interface (Auto Mode, Manual Mode, Bypass Mode). We must know all of
the components to make us quite familiar with the automation system to transfer the raw work
piece from Automatic Storage and Retrieval Station (ASRS) to the FMS station. The more the
user knows about basic CNC machining practice and EDU CIM System, the easier it will be to
adapt to these two things.

3.0 Introduction:
CNC milling is a specific form of computer numerical controlled (CNC) machining.
Milling itself is a machining process, like drilling, milling uses a rotating cylindrical cutting tool.
However, the cutter in a milling machine is able to move along multiple axes, and can create a
variety of shapes, slots and holes. In addition, the work-piece is often moved across the milling
tool in different directions, unlike the single axis motion of a drill.

CNC milling devices are the most widely used type of CNC machine. Typically, they are
grouped by the number of axes on which they operate, which are labeled with various letters. X
and Y designate horizontal movement of the work-piece (forward-and-back and side-to-side on a
flat plane). Z represents vertical, or up-and-down, movement, while W represents diagonal
movement across a vertical plane. Most machines offer from 3 to 5 axes, providing performance
along at least the X, Y and Z axes. The device is extremely useful because it is able to produce
shapes that would be nearly impossible using manual tooling methods. Computer numeric
controlled machining centers are used to produce a wide range of components, and tooling costs
involved have continued to become more affordable. In general, large production runs requiring
relatively simple designs are better served by other methods, although CNC machining can now
accommodate a wide range of manufacturing needs. CNC milling centers are ideal solutions to
everything ranging from prototyping and short-run production of complex parts to the fabrication
of unique precision components.
In CIM Laboratory an EDU VR1 CIM-110, which is a Computer Integrated
Manufacturing (CIM) system for the purpose of teaching and learning has been setup. The EDU
CIM System is an automation system to transfer the raw work piece from Automatic Storage and
Retrieval Station (ASRS) to the FMS station which consists of a 6 D.O.F robot arm and a CNC
Milling.
The main reason why this lab is being done is to demonstrate the ways to use the CNC
milling machine. Besides, the CNC machine operation safety and the start-up procedure of the
EDU VR1 Mill CNC machine is being described. The other objective is to prepare the EDU VR1
Mill CNC machine ready in the Automatic Mode of the CIM System. From this lab
demonstration, we fully understand the steps from starting the machine until it is being shut
down. Now we are quite familiar with the automation system and the relationships between the
CNC milling machine and the EDU CIM System.

4.0 Materials:

SIEMENS SINUMERIK 808D Milling

- The scope of applications ranges from basic standardized milling machines and basic
machining centers to cycle-controlled turning machines through to basic full-CNC lathes.

PC (installed with CIM System with SCADA Interface)

- To run program with Auto Mode or Manual Mode to start the process

6-Axis Mitsubishi Robot (pick & place)

- Various kinds of operation can be programmed, multitask processing, which enables the
parallel processing of robot operation, external input/output signal processing and
external device communications programs at the same time.

5.0Results & Discussion:

1)

List down the precautions to be taken during the CNC milling operation.
o Must have knowledge about CNC Milling Machine and CIMS before

handling the machine.

o CNC machine door must be closed during the operation, if not, the operation

will not start or stuck.

o A major cause of crashes is setting the tool or fixture offset incorrectly. Pay

particular attention to moves at the start of program and immediately after a

tool change as the tool moves towards the part. Use single-block mode to
advance through the program one line at a time until the tool is at cutting
depth.
o Remain at the machine with a hand on or near the emergency stop button.

Stop machine motion at the first sign of trouble.

o No horseplay or practical jokes are allowed in the shop. Wear ANSI approved

safety glasses or ANSI safety approved glasses with side shields. We must
wear safety glasses at all times in the shop, not just when at the machine.
o Do not wear flip flops or sandals. Leather shoes are best. Steel toe shoes are

not necessary unless handling heavy objects that would crush regular shoes.
o Remove rings and watches when at the machine.
o Never wear gloves as they can be caught in the machine. Latex gloves are

acceptable.

2)

Explain the preparation procedure for the EDU VR1 Mill CNC machine is ready
for the CIM System.

1. The main switch of the machine and control is turned on. The machine power
button is located in the upper-left corner on the control face.
2. After power on, the machine must first be referenced! After power on, the
machine will be in the reference point approach mode (default). If the axis is not
referenced, the non-referenced symbol (circle) is dis-played between the axis
identifier and the value. The axes are referenced with the corresponding axis
traversing keys. The traversing direction and keys are specified by the machine
manufacturer. After completing the referencing procedure for all axes, the
referenced symbol is displayed next to the axis identifier.
3. After returning to JOG mode, the axis traversing keys is used to move the
machine manually.

4. The machine can now be operated in JOG mode. During normal operation (JOG),
the referenced symbol is not shown on the screen.
5. A tool must be loaded to the spindle in a jog mode. After that, go for AUTO mode.
6. The CNC program from your computer is downloaded to the machine control. In
this lab, a CIM program is already loaded into the machine. The CIM program is
executed.
7. The CYCLE START key on the MCP is pressed to run the program, using extra
caution until the program is proven to be error-free.
8. Tools from the spindle is removed, the work area is cleaned, and the machine is
properly shut down.

THE FLOWCHART FROM ASRS TO FMS

CIM System
with SCADA
Interface
Auto Mode
Manual Mode

6-Axis Mitsubishi
Robot (pick &
place)

Automatic Storage
and Retrieval

Robot Zero Return

Station (ASRS)

Auto Mode Switching

Robot Zero Return

Material Handling

Pallet Tracking Station

Continuous-loop
Conveyors

Machine
Tending
Station
(FMS)

The stop station allows the

PLC to control and monitor
the flow of pallets on the
conveyor with the help of
sensors

to mount the stop

stations and carry
the pallets.

3) Discuss the relationship between the CNC milling machine and the Computer
Integrated Manufacturing (CIM) System
In the industrial serial production of mass volumes of goods, the use of one or
more robots is a must to ensure that the manufacturing processes are working at
maximum efficiency. In our training system a robot operates in combination with CNC
machines. This automated milling station can be used as a stand-alone work cell, or
integrated within a CIM system. When used in a CIM system, the robot loads and unloads
parts to and from the CIM conveyor in addition to performing milling and part
manipulation tasks.
Optional automation accessories permit integration of FMS stations, e.g. for the
coupling of the CNC machine to the robot station, which then performs the loading and
unloading of the CNC machine.
Subjecting the individual station to full automation is the first step towards total
integration in a production line. This is achieved with the aid of a robot that functions as a
link between the machining equipment and the station. The robot undertakes the steady
loading of the workpiece blanks and subsequently the unloading of the machined (milled
and cut) workpieces. The finished workpieces are then safely loaded into the magazine of
the corresponding FMS station.
In all of the CIM systems, the working ranges of the robot are safeguarded by
safety packages designed specifically for this application. As soon as the infrared beams
of the light curtain are interrupted, the robot is disabled. The robot also immediately stops
its work when the front flap of the milling machine is opened, thus preventing injuries
and material damage.
After understanding the relationships between the CNC milling machine and
CIM, you will be able to construct, program, simulate and ultimately manufacture
workpieces by yourself. The transition from individual machine solutions to full
integration into the FMS system via robot proceeds without a hitch so that there is
practically no additional technical know-how required.

For overall, the ASRS storage station (a floor-mounted or a table top automated
storage and retrieval (ASRS) system) is dedicating the Cartesian robot transfers parts
between storage cells and conveyor pallets stopped at the ASRS station. The robot is
controlled the CIM System with SCADA Interface.
This package can be used as a stand-alone work cell, or integrated within a CIM
system. The robot tends the CNC machine and performs other part manipulation and/or
assembly tasks. When used in a CIM system, the robot loads and unloads parts to and
from the CIM conveyor. The robot is mounted on a linear slide base for mobility and
larger work area. The robot is controlled by Controller-USB and by a dedicated ASRS
software module in the OpenCIM software. Any of the MTS stations can be provided as a
standalone FMS.
The assembly and QC station is equipped with a variety of assembly and quality
control devices as well as with local storage devices. This turnkey station gives students
training and skills in assembly, quality control, robotic programming and automated
manufacturing systems. This automated welding station can be used as a stand-alone
workcell, or integrated within a CIM system. When used in a CIM system, the robot
loads and unloads parts to and from the CIM conveyor in addition to performing arc
welding and part manipulation tasks. The conveyor frame is constructed of extruded,
black anodized aluminum, and its moving belt is a double flexible-chain rail.
The PLC (Programmable Logic Controller) can control and monitor the flow of
pallets on the conveyor with the help of sensors and actuators that are built into the stop
stations. The stop station allows the PLC to control and monitor the flow of pallets on the
conveyor with the help of sensors and actuators that are built into the stop stations.
The OpenCIM software is a computer-integrated systems management solution
that contains all the elements found in fully-automated facilities. Shop floor management
controls the operation of all the elements of automated factory. Administrative software
connects the shop floor management to the production facilitys Enterprise Resource
Planning (ERP). The OpenCIM software contains an ERP package which breaks down
customer orders to analyse bill of materials, check availability of raw materials, produce
vendors purchase order and schedule production based on expected lead times.

The ASRS 36u has 36 cells arranged in six rows. Each cell can store a partholding template. The 36 templates supplied with the system have pin holes that allow the
user to customize the template's holding area to accommodate objects of various shapes
and sizes.
A template buffer supplied with the system can be attached to a CIM conveyor or to a
table in a stand-alone ASRS/robotic work cell.

6.0 Conclusion:
As a conclusion, from this lab, we are now familiar with the CNC usage and quite clear
about the EDU CIM System. We have the knowledge about the CNC machine operation safety
and the start-up procedure of the EDU VR1 Mill CNC machine. We are quite exposed on how to
prepare the EDU VR1 Mill CNC machine ready in the Automatic Mode of the CIM System. We
are also fully aware that a CNC user must understand and know how the CNC machine tool
being utilized and how the CNC machine works. We must consider the basic areas including the
machine's most basic components, the machine's directions of motion (axes, any accessories
equipped with the machine and the programmable functions that are indicated with the machine.
We know that this CNC machine has improved automation and has its flexibility.
About the EDU VR1 CIM-110 (EDU CIM System), we are introduced to 6-Axis
Mitsubishi Robot with its advanced function (Auto Mode Switching, ASRS, Vision Inspection
Station, etc). We must know all of the components in CIM and CNC milling machine to make us
quite familiar with the automation system to transfer the raw work piece from Automatic Storage
and Retrieval Station (ASRS) to the FMS station. The more we know about basic CNC
machining practice and EDU CIM System, the easier it will be to adapt to these two things.

7.0 References:

Book
Mikell P.Groover, Automation, Production Systems, and
Computer Integrated
Manufacturing, Prentice Hall International, Inc., USA,
2001

Web

http://www.intelitek.com/pdf/DS01_BU_CIM-A_100761.pdf
http://wwwme.nchu.edu.tw/~CIM/courses/Computer
%20Integrated%20Manufacturing/Chapter2%20-CIMintroduction.pdf
http://www.lucasnuelle.com/index.php/fuseaction/download/lrn_file/11061
5_cim_automation_gb.pdf