1.

0 TITLE
CNC Milling (Non Traditional Machining)

2.0 OBJECTIVE

a To design a basic NC program for CNC Milling.

b To machine a product using the CNC Milling.

1
3.0 INTRODUCTION

3.1 Background

Non-traditional manufacturing processes is defined as a group of processes that

remove excess material by various techniques involving mechanical, thermal,
electrical or chemical energy or combinations of these energies but do not use a sharp
cutting tools as it needs to be used for traditional manufacturing processes. Extremely
hard and brittle materials are difficult to machine by traditional machining processes
such as turning, drilling, shaping and milling. Non-Traditional Manufacturing
Processes or non-conventional Manufacturing processes mostly remove material in the
form of chips by applying forces on the work material with a wedge shaped cutting
tool that is harder than the work material under machining condition.

CNC milling is a specific form of computer numerical controlled (CNC)

machining.Milling itself is a machining process similar to both drilling and cutting,
and able to achieve many of the operations performed by cutting and drilling
machines. Like drilling, milling uses a rotating cylindrical cutting tool. Generally
CNC milling process has 3-axes to find it coordinate. It represent by the alphabet X,Y
and Z. These devices are extremely useful because they are able to produce shapes that
would be nearly impossible using manual tooling methods. Some advantages of this
type of machine are that it is automatically cool down. It is also very precise with
typically 0.0001 inch. It is also easy to multiply copies, easy to create similar object
and need fewer worker to handle it

2
 Figure 3.1: CNC milling machining

CNC milling devices are also 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. Advanced machines, such as 5-axis milling centers, require CAM programming
for optimal performance due to the incredibly complex geometries involved in the
machining process. These devices are extremely useful because they are able to
produce shapes that would be nearly impossible using manual tooling methods. Most
CNC milling machines also integrate a device for pumping cutting fluid to the cutting
tool during machining.

3
 3.2 Theory

Common G codes and M codes for CNC machine controls

CNC G codes

G00 - Positioning at rapid speed; Mill and Lathe

G01 - Linear interpolation (machining a straight line); Mill and Lathe
G02 - Circular interpolation clockwise (machining arcs); Mill and Lathe
G03 - Circular interpolation, counter clockwise; Mill and Lathe
G04 - Mill and Lathe, Dwell
G09 - Mill and Lathe, Exact stop
G10 - Setting offsets in the program; Mill and Lathe
G12 - Circular pocket milling, clockwise; Mill
G13 - Circular pocket milling, counterclockwise; Mill
G17 - X-Y plane for arc machining; Mill and Lathe with live tooling
G18 - Z-X plane for arc machining; Mill and Lathe with live tooling
G19 - Z-Y plane for arc machining; Mill and Lathe with live tooling
G20 - Inch units; Mill and Lathe
G21 - Metric units; Mill and Lathe
G27 - Reference return check; Mill and Lathe
G28 - Automatic return through reference point; Mill and Lathe
G29 - Move to location through reference point; Mill and Lathe (slightly different for each
machine)
G31 - Skip function; Mill and Lathe
G32 - Thread cutting; Lathe
G33 - Thread cutting; Mill
G40 - Cancel diameter offset; Mill. Cancel tool nose offset; Lathe
G41 - Cutter compensation left; Mill. Tool nose radius compensation left; Lathe
G42 - Cutter compensation right; Mill. Tool nose radius compensation right; Lathe
G43 - Tool length compensation; Mill
G44 - Tool length compensation cancel; Mill (sometimes G49)
G50 - Set coordinate system and maximum RPM; Lathe
G52 - Local coordinate system setting; Mill and Lathe
G53 - Machine coordinate system setting; Mill and Lathe
G54~G59 Work piece coordinate system settings #1 t0 #6; Mill and Lathe
G61 - Exact stop check; Mill and Lathe
G65 - Custom macro call; Mill and Lathe
G70 - Finish cycle; Lathe
G71 - Rough turning cycle; Lathe
G72 - Rough facing cycle; Lathe
G73 - Irregular rough turning cycle; Lathe
G73 - Chip break drilling cycle; Mill
G74 - Left hand tapping; Mill
G74 - Face grooving or chip break drilling; Lathe
G75 - OD groove pecking; Lathe
G76 - Fine boring cycle; Mill

4
G76 - Threading cycle; Lathe
G80 - Cancel cycles; Mill and Lathe
G81 - Drill cycle; Mill and Lathe
G82 - Drill cycle with dwell; Mill
G83 - Peck drilling cycle; Mill
G84 - Tapping cycle; Mill and Lathe
G85 - Bore in, bore out; Mill and Lathe
G86 - Bore in, rapid out; Mill and Lathe
G87 - Back boring cycle; Mill
G90 - Absolute programming
G91 - Incremental programming
G92 - Reposition origin point; Mill
G92 - Thread cutting cycle; Lathe
G94 - Per minute feed; Mill
G95 - Per revolution feed; Mill
G96 - Constant surface speed control; Lathe
G97 - Constant surface speed cancel
G98 - Per minute feed; Lathe
G99 - Per revolution feed; Lathe

CNC M Codes

M00 - Program stop; Mill and Lathe

M01 - Optional program stop; Lathe and Mill
M02 - Program end; Lathe and Mill
M03 - Spindle on clockwise; Lathe and Mill
M04 - Spindle on counterclockwise; Lathe and Mill
M05 - Spindle off; Lathe and Mill
M06 Tool change; Mill
M08 - Coolant on; Lathe and Mill
M09 - Coolant off; Lathe and Mill
M10 - Chuck or rotary table clamp; Lathe and Mill
M11 - Chuck or rotary table clamp off; Lathe and Mill
M19 - Orient spindle; Lathe and Mill
M30 - Program end, return to start; Lathe and Mill
M97 - Local sub-routine call; Lathe and Mill
M98 - Sub-program call; Lathe and Mill
M99 - End of sub program; Lathe and Mill

5
4.0 APPARATUS

Cutting
tool

Holding
Work workpiec
piece e

Figure 4.1: CNC Milling machine with parts labelled

Machine
controller

Figure 4.2: Machine Controller

6
4.1 INDUSTRIAL APPARATUS

1.

Figure 4.1.1: Okuma MA650VB 50 Taper (aerospace parts)

-50-taper CNC mills that deliver 800 foot-pounds of torque for heavy duty
materials like titanium, invar, and Inconel.

2.

Figure 4.1.2: Mori Seiki MV Junior CNC Mill (automotive parts)

7
- Creating new and recreating old race car components requires the
equipment that takes raw material stock and transforms it into the
component needed on the car.

3.

Figure 4.1.3: Micro grinding reminiscent of Swiss-type machine

(medical parts)

- The medical field uses CNC milling machines to build customized

precision parts such as prosthetic knee and hip replacement joints,
mold cavities and cores, specialized tools and equipment for
surgery, and more.

8
5.0 EXPERIMENTAL PROCEDURE

1. The work piece is prepared as shown in the figure 5.1.

Figure 5.1: work piece of wooden block

2. The pattern is designed in computer by using software CATIAV5 and

a writing is created on the work piece (in computer).
3. The coding (program) is generated to enable the CNC milling
machine read the program and doing the milling processes.
4. The coding (program) which generated by the computer is
transferred and uploaded to the CNC milling machine and the CNC
milling machine now enables read the coding.
5. The work piece now is placed on the workplace and is clamped by a
clamp attached on the CNC milling machine.
6. The path which travelled by the edge of the drill of the CNC milling
machine is set up in the machine before the starting the machining
process.

9
7. The datum in direction x, y and z is set up by hitting the drill to the
work piece a little as shown in figure 5.2 and then the datum is set
up in the machine.

Figure 5.2: shows how to make a datum on the work piece before
datum is set up in the CNC milling machine

8. The milling process is started by pushing start button and the

thickness of the work piece is changed from 20mm to 15mm and
then milling process is continued until it is the milling process is
finished.
9. The work piece now is taken and ready to be observed.

10
6.0 RESULTS AND DATA ANALYSIS

%
O1000
( ********************************************************************** )
(* INTELLIGENT MANUFACTORY SOFTWARE WWW.IMS-SOFTWARE.COM
*)
(* IMSPOST VERSION : 7.4R *)
(* USER VERSION : 1 *)
( ********************************************************************** )
N1 G49 G64 G17 G80 G0 G90 G40 G99
( TOOL DATA : T1 END MILL D 1 )
N2 T0001 M6
N3 X12.266 Y24.091 S70 M3
N4 G43 Z10.01 H1
N5 G1 G94 Z.01 F300.
N6 X12.173 Y24.364 Z-.067
N7 X11.959 Y24.811 Z-.2
N8 X11.927 Y24.863 F1000.
N9 X11.996 Y24.705
N10 X12.019 Y24.646
N11 X12.164 Y24.189
N12 X12.179 Y24.133
N13 X12.284 Y23.639
N14 X12.295 Y23.573
N15 X12.371 Y22.809
N16 X12.374 Y22.741

11
N17 X12.363 Y21.982
N18 X12.358 Y21.913
N19 X12.274 Y21.268
N20 X12.331 Y21.458
N21 X12.425 Y21.942
N22 X12.474 Y22.464
.
.
.

N9276 X59.706 Y31.996

N9277 X59.747 Y31.963
N9278 X59.767 Y31.945
N9279 X59.941 Y31.759
N9280 X59.958 Y31.738
N9281 X59.99 Y31.695
N9282 X60.004 Y31.672
N9283 X60.131 Y31.431
N9284 X60.137 Y31.419
N9285 X60.148 Y31.394
N9286 X60.153 Y31.382
N9287 X62.803 Y24.125
N9288 X62.805 Y24.121
N9289 X62.808 Y24.112
N9290 X62.809 Y24.107
N9291 X62.833 Y24.032
N9292 X62.837 Y24.016
N9293 X62.845 Y23.984
N9294 X62.848 Y23.968
N9295 X62.885 Y23.701
N9296 X62.887 Y23.674

12
N9297 X62.888 Y23.619
N9298 X62.886 Y23.592
N9299 X62.851 Y23.324
N9300 X62.846 Y23.297
N9301 X62.831 Y23.245
.
.
.

N9992 X55.293 Y22.163

N9993 X62.441
N9994 X62.46 Y22.162
N9995 X62.652 Y22.144
N9996 X62.701 Y22.133
N9997 X62.98 Y22.033
N9998 X63.019 Y22.014
N9999 X63.188 Y21.908
N1 X63.227 Y21.876
N2 X63.403 Y21.69
N3 X63.434 Y21.647
N4 X63.565 Y21.404
N5 X63.575 Y21.381
N6 X64.405 Y19.2
N7 X64.826 Y18.217
N8 X65.018 Y17.847
N9 X65.11 Y17.732
N10 X65.25 Y17.671
N11 X65.453
N12 X65.594 Y17.715
N13 X65.738 Y17.824

13
N14 X65.861 Y17.981
N15 X65.889 Y18.057
N16 X65.886 Y18.187
N17 X65.81 Y18.52
N18 X65.546 Y19.277
N19 X63.912 Y23.316
N20 X64.004 Y23.353
N21 X64.096 Y23.391
N22 X61.032 Y30.958
N653 X62.187 Y22.925
N654 X61.965 Y22.76
N655 X61.724 Y22.669
N656 X61.49 Y22.64
N657 X56.241
N658 X56.159 Y22.643
N659 X55.919 Y22.694
N660 X55.67 Y22.813
N661 X55.481 Y22.983
N662 X55.329 Y23.213
N663 X55.248 Y23.467
N664 X55.237 Y23.744
N665 X55.292 Y23.982
N666 X57.894 Y31.237
N667 X58.031 Y31.494
N668 X58.216 Y31.686
N669 X58.448 Y31.824
N670 X58.71 Y31.895
N671 X58.965 Y31.893
N672 X59.226 Y31.823
N673 X59.381 Y31.813 Z-.958

14
N674 X59.529 Y31.863 Z-.916
N675 X59.647 Y31.965 Z-.874
N676 X59.716 Y32.105 Z-.832
N677 Z9.168
N678 G0 Z10.
N679 M5
N680 M30
N681 M2
N682 M30
%

15
 Step 1

Step 2

Step 3

Figure 6.1: Process through CNC milling machine

7.0 DISCUSSION OF RESULTS

16
 In this experiment, our aims are to learn and understand the use and
capabilities of computer numerical control (CNC) milling machine.There
are three ways to get the NC program which is APT , manual and (CAD). In
this experiment, we were teach to used CAD as to find and develop the
NC program. CAD is used to make a design of a product. In CAD, it involves
a special symbolic programming languages or codes that determine the
coordinate points of corner, edges and surfaces of the work piece. Once
the design is completed, we supposedly transfer the coding that we made
using ISO NC programmed to the CNC milling machine. All the data about
the process from the beginning to the end is included in those codes and
wrong coding will damage the work piece. After finish the design by using
CAD, . we transfer the NC program to the (CNC) milling machine to
proceed our design on the surface of the work piece.

In order to prevent damage, we need to view the simulation on the

CNC screen and do some final editing so that the milling machine is
operating in a good condition as we will obtain perfect work piece.. The
machines cutting tool might break. We have to set up cutting tool, cutting
fed, cutting speed , spindle speed that is suitable with the specimen to
avoid error occur during the process.

From the experiment, we can say that our product is perfect and
thus our experiment is consider to be success. The process of CNC milling
machine show that, there are lot advantages to produce any product with
the help of CAD as a design and produce the right NC program.
Furthermore, training in the use of CNCs is available through the use of
virtual software, this software that allows the operator to practice using
the CNC machine on the screen of a computer. Design changes are almost
easier to amend because it can be done by make simple adjustment at the
CNC program. Finally, this machine is easy to operate which key in the
coding to operate.

17
8.0 CONCLUSION

Based on the experiment, all objective that we coincide to design a

basic NC program for CNC milling and to machine a product using the CNC
milling before doing the experiment are achieved.. We consider that both
of the NC programming and CNC Milling Machine were used to produce the
desired products.

There are some defects will occur to the desired product, it depend
on the types of design. The sharp or edges product cant be proceed
because it will effect the surface of the product which is not completely
follow the design. Students who are following the experiment can also see
with their eyes how to do CNC milling processes while practicing safety
precaution before do the machining processes. This experiment also can
improves their understanding about the CNC milling and they can use the
knowledge that they learn from this session in real engineering world to
become succesful engineers. Students also can appreciate the knowledge
that they learn from this lab session.

The use of CNC help the process to run smoothly and provide other
advantages. It improves automation, removing the need of an operator for
all but a few parts of the work. CNC machines can be left unattended for
hours or even days if necessary, allowing operators to focus on other
tasks. CNC machines can be used continously 24 hours a day, 365 days a
year and only need to be switched off for occasional maintenance. But this
technology is costly and not suitable for small scale production.

18
9.0 RECOMMENDATION

One of the recommendation is make sure the speeds and feeds are
consistent to increase the quality of the CNC milling machine and will
produce a huge difference on the surface finish. Getting the right speeds
and feeds is just as important to obtain a good surface finish. Sometimes
as the work piece is heated up, it will affected due to thermal expansion.
As the coolant cools the tools it also cools the work piece and this can
increase the accuracy as the work piece produce good surface finish.
Beside that, coolant also act as lubrication for the tool and work piece
interface.

All the tools should be kept clean and well maintained. The
machining tools can be maintain by applying oils to make sure no rusting
part. After using the tools, students should clean the used tools to keep
the cleanliness of the tools. Next recommendation is laboratory
cleanliness. The laboratory should always be keep clean and tidy. The floor
should be clean and make sure that there is no other material that can
cause to a disaster in the lab.

Other recommendation is lecturer and technician should provide a

simple instruction on carry out the experiment. The instruction for
designing the product and procedure on using the machine and other
equipment should be clear and understandable so that the students could

19
run the process according to the instructions prepared even without guide
from the lecturer.

Students also should prepared before entering the laboratory by

study the lab sheet given and any information about the experiment so
that it is easier for lecturer and also students to conduct the experiment
when the students understand what they are doing. These improvements
and recommendations could make the students learn more about the
process and could gain themselves a lot more information about the
experiment which can provide them more knowledge that can be use in
industry.

10.0 REFFERENCES

1. Mike Mattson, CNC Programming: Principles and Applications,

Delmar, Cengage Learning, CliftonPark, New York, 2010.
2. Milling(machining). Retrieved November 20, 2016, from Wikipedia
https://en.wikipedia.org/wiki/Milling_(Machining)
3. Mikell P. Groover, Principles of Modern Manufacturing, 4thEdition,
Wiley
2011
4. Ostwald, P. F., and J. Munoz, Manufacturing Processes and Systems, 9
th ed. John Wiley &Sons, New York, 1997.
5. Kalpakjian, S., and Schmid S. R. Manufacturing Processes for
Engineering Materials, 5thed. Pearson Prentice Hall, Upper Saddle
River, New Jersey, 2007.
6. Kardes, N., & Altintas, Y. (2007). Mechanics and dynamics of the
circular milling process. Journal of Manufacturing Science and
Engineering, 129(1),21.

20
7. Machining Retrieved November 20, 2016, from Wikipedia,
https://en.wikipedia.org/wiki/Machining.
8. Werner, A., & Poniatowska, M. (2015). Improving accuracy of
curvilinear profiles machined on CNC milling centres.
Mechanik725/338-725/346.
9. Hitomi, K. (1996). Manufacturing systems engineering: A unified
approach to manufacturing technology, production management
and industrial economics (2nd ed.) Bristol, PA: Florence, Kentucky,
USA,: Taylor & Francis.
10. Mazumdar, S.K. (2001). Composites manufacturing: Materials,
product and process engineering, Boca Raton, FL: Taylor & Francis.

21