FACULTY OF MECHANICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA (UITM)

LABORATORY REPORT

PROGRAM : Bachelor of Engineering (Hons) Mechanical (EM220)

COURSE : Manufacturing Processes Laboratory
COURSE CODE : MEM564
LABORATORY NAME : Machining
LECTURER NAME : Radzuan A. Rahman
TITLE OF EXPERIMENT : CNC Milling (Non Traditional Machining)
GROUP : EMD5M9A/10

NO. STUDENT NAME STUDENT ID NUMBER SIGNATURE

1 NOR NABILAH BINTI CHE ABD RAHIM 2015829412
2 NUR AFIQAH BT KAMARUDZMAN 2015217382
3 NUR DHANIA BT NADZRI 2015208522
4 NUR SHAZWANI BT ALIDZA 2015839554
5 NUR ZAKIAH BINTI MOHD RAFEE 2015208746

DATE OF PRACTICAL SESSION STAFF CERTIFICATION (SIGNATURE)

DATE OF REPORT SUBMISSION STAFF CERTIFICATION (SIGNATURE)

2
 TABLE OF CONTENTS

TABLE OF CONTENTS......................................................................................................1

1.0 TITLE....................................................................................................................2

2.0 OBJECTIVES..........................................................................................................2

3.0 INTRODUCTION...................................................................................................2

4.0 APPARATUS..........................................................................................................4

5.0 EXPERIMENTAL PROCEDURE...............................................................................4

6.0 RESULTS & DATA ANALYSIS..................................................................................4

7.0 DISCUSSION OF RESULTS.....................................................................................5

8.0 CONCLUSION.......................................................................................................9

9.0 RECOMMENDATION............................................................................................9

10.0 REFERENCES......................................................................................................10

1
1.0 TITLE
CNC Milling (Non-Traditional Machining)

2.0 OBJECTIVES
i. To design a basic NC program for CNC Milling
ii. To machine a product using the CNC milling

3.0 INTRODUCTION
A non-traditional manufacturing process is defined as a group of process that
remove accessed material by various techniques based on different source of
energy. The cutting source may in the form of mechanical, thermal, electric or
chemical energy or combinations of these energies without any direct contact
of sharp cutting as in traditional machining. Extremely hard and brittle
materials are difficult to machine by traditional machining process such as
turning, drilling, shaping and milling. Non-traditional machining processes are
graphed in advanced manufacturing processes. It is employed when
traditional machining processes are not feasible and due to certain
satisfactory justification to special reasons.

Numerical control is a method of controlling the movement of the machine.

This program controlling the movement of the component on the machine by
directly inserting the code of instructions into the system. The system
interprets data and convert them to output signal. In numerical control
operations, data concerning all aspects of the machining operation, such as
tool location, speeds, feeds, and cutting fluids are stored on hard disk.

2
 Figure 3- 1 CNC Milling Machine

The instructions code can be performed by computer software such as CATIA

that produce numerical code from geometry data files. The program contains
the following instructions and command:
i. Geometric instructions pertain to relative movements between the
tools and the workpiece.
ii. Processing instructions concern spindle speeds, feeds, cutting tools,
cutting fluids and so on.
iii. Travel instructions pertain to the type of interpolation and to the
speed of movement of the tool or the worktable.
iv. Switching instructions concern the on-off position for coolant supplies,
direction or lack of spindle rotation, tool changes, workpiece feeding,
clamping and so on.

Computer-aided Manufacturing (CAM) involves the use of computers to assist

in all phases of manufacturing a product. The combination of Computer-aided
Design (CAD) and CAM allows the transfer of information from the design
stage to the planning for manufacturing stage. There is no necessity to enter
the data on part geometry manually. The database developed during CAD is
stored and further processed by CAM into the relevant data and instructions
for the operating and controlling production machinery, material-handling
equipment and automated testing and inspection for product quality.

3
4.0 APPARATUS
i. NC Program
ii. Machine controller
iii. Rough stock
iv. CNC milling machine
v. Work holding devices
vi. Cutting tool

5.0 EXPERIMENTAL PROCEDURE

1. The NC programming was designed using CATIA software.
2. The NC program was uploaded in Computer Aided Manufacturing (CAM).
3. The workpiece was prepared and the machine was setup.
4. Milling process was started.

6.0 RESULTS & DATA ANALYSIS

Developed NC Program using CATIA software

End product of machined rough stock

4
7.0 DISCUSSION OF RESULTS
Computer Aided Machining or Manufacturing (CAM) refers to the use of
various software packages to create toolpaths and NC code to run a CNC
controlled machine, based on 3D computer model (CAD) data. When the two
are used together, this is generally referred to as CAD/CAM. CAM does not
actually run the CNC machine, but just creates code for it to follow. It is also
not an automatic operation that imports your CAD model and spits out the
correct NC code.

Most NC today is computer numerical control (CNC), in which computers play

an integral part of the control. In modern CNC systems, end-to-end
component design is highly automated using computer-aided design (CAD)
and computer-aided manufacturing (CAM) programs.

The CNC machine is programmed by using CAM software which uses the
software to apply tool paths to a 3D or 2D model of the part desired. FANUC
is developed as an early numerical control (NC) and servo systems, it is an
acronym for factory automation numerical control. A special relatively simple
computer language that a CNC machine can understand and execute is NC
code. These languages were originally developed to program parts directly at

5
the machine keyboard without the aid of a CAM program. They tell the
machine what moves to execute, one by one, as well as controlling other
machine functions such as spindle and feed speeds, coolant. The most
common language used in this workshop session is G-code and M-code.

From the result, the NC program starts with a ‘%’ symbol which indicates
FANUC language, and the first to 6th commands (N1-N6) are inputs of the
tool bit detail and positioning of the axis of origin which includes:
G4 Tool length compensation G40 Cutter compensation cancel
9 cancel
G6 Cutting mode G99 R point return
4
G1 Circular interpolation plane M6 Start tool change
7 selection XY
G8 Canned cycle cancel M3 Spindle on clockwise
0
G0 Rapid positioning G43 Tool length compensation (+)
G9 Absolute positioning mode G1 Linear interpolation
0

In the end of the machining, the CNC program instructed the machine to
switch off the spindle (M5) and restart the program (M2).

In this workshop, poly (methyl methacrylate) (PMMA), also known as acrylic

or acrylic glass as well as by the trade names Plexiglas, Acrylite, Lucite, and
Perspex is used. It is a transparent thermoplastic often used in sheet form as a
lightweight or shatter-resistant alternative to glass. The material that had
been removed is called "chips" and it will usually be recycled.

6
 Figure 7- 2 Type of material used; Perspex.

Once the programming is done, it is fed into a post processor which will turn
the CAM program into the M and G code the machine can read. The codes are
then uploaded into the CNC machine along with all the cutting tools needed,
raw material and work holding needed to hold the raw material. Then the
machine is put into automatic mode and start the program to make the part.

Figure 7- 3 The codes are uploaded into the CNC machine & being read to perform the process
automatically

7
 Figure 7- 4 The workpiece while being carved into desired shape

Lubricant is used as all moving parts in a machine require lubrication, that is,
the application of oil to reduce friction between them. As it reduces friction,
the Perspex used wont melt from heat produced between the tools.

Figure 7- 5 Lubricant is applied to reduce friction between the workpiece and the tool bit

The quality of the end product of the machining process is not that satisfying
as it doesn’t resembles the CAD file of the product. This might be due to the
errors during the process setup. To get a better finish, the fine cut should be
decreased.

8
8.0 CONCLUSION
In the industrial world, time is money. Where all business owners would like
to have an abundance of both. Utilizing the CNC machine monitoring and
reporting systems, it will maximize the production efficiency, train production
personnel to be aware of their inactivity, and provide our production
management team with the tools to improve the output.

In conclusion, the objective of this experiment has been successfully achieved

as a product had been made by using a basic NC program design on the CNC
Milling machine. The using of the NC program in CNC Milling help a lot in
reducing the time and make it simple in handling the milling process. The
machine can be used to produce complex shapes and precise product with
high dimensional accuracy. Besides, it can reduce the scrap loss. Milling
machines are being replaced rapidly by this CNC Machines which are more
versatile and capable of milling, drilling, boring and tapping with repetitive
accuracy.

9.0 RECOMMENDATION
Catia, computer aided design (CAD) is a software used to draw or design the
shape of the product to be machined. The data or design have to be
transferred manually from the computer to the machine via thumb drive.
Some of the time, the data transferred cannot be read by the machine, due to
some errors during the transfer process. As a recommendation, we can
attached the design software to the machine, so that we don't have to
transfer the data to the machine manually. This will minimize the error and
will reduced time taken to transfer the data using transfer tools.

During the process, the workpiece will be machine for a long period of time
and it can make the cutting tool blunt. Besides, it can also produce heat,
which can melt or break the workpiece also, producing a rough surface finish.
To prevent that from occurring, lubricant or oil can be introduced during the
9
 cutting process. Currently, applying the lubricant is done manually by hand.
This is a hassle as an operator need to be there during the machining process
to keep an eye on the workpiece as the machining process runs. As a
recommendation, we can install an automated lubricant system which can
cool the tool bit and the workpiece efficiently.

Some of the workpiece or product is extremely complex so there was plenty

of chips after the machining process. The chips was scattered all over the
machine. As recommendation, we can put additional component such as a
box or tray under the machine so that it will make it easier to clean up the
chips.

10.0 REFERENCES
1. Serope Kalpakjian, Manufacturing Engineering and Technology, 6th
Edition, Illinois Institute of Technology, Prentice Hall, 2010.

2. John A. Schey, J.A., "Introduction to Manufacturing Processes", 5th

Edition, McGraw-Hill, 2000.

3. Mikell P Groover, Principles of Modern Manufacturing, SI Version, 4th

Edition, John Wiley & Son, Inc., 2011.

4. P N Rao, Manufacturing Technology, Metal Cutting and Machine Tools,

Universiti Teknologi Mara, Malaysia, Tata Mc Graw Hill, 2000.

10