ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people, who directly or indirectly contributed in

the development of this work and who influenced my thinking, behaviour and acts during the
course of study.

I express my sincere gratitude to the college for providing me an opportunity to undergo

summer training at “KARM MACHINE TOOLS PVT. LTD”.

And I also express my sincere gratitude to Dr. Nidhi Singhal (The Director) and Mr. A.K
Pathak (The Dean of Academic Affairs) for providing me a Platform like KMT to increase
my technical knowledge as well as gaining practical knowledge in CNC Machine Tools,
which will help me to achieve a better job opportunity in my field.

I also extend my sincere appreciation to Mr. R.K Saxena (Head of Department) & Faculty
of Electrical Dept. who provided his valuable suggestions and precious time in accomplishing
my training report.

Lastly, I would like to thank the almighty and my parents for their moral support and my
friends with whom I shared my day-to-day experience and received lots of suggestions that
my quality of work.
 ABSTRACT

Industrial Training is meant to expose the students of engineering of the actual industrial
processes about which they have been studying in detail from their semesters .They have
spent the last 3 years in gaining theoretical knowledge of various manufacturing and
assembly process.

The eight weeks of training has exposed us to the actual applications of various studies. The
training period has been very interesting wherein we got to know how the final product
comes to the market.

Each product undergoes a number of qualities control test to bring in uniformity and quality.

Each field requires skillfully handling and training given at each steps which will help us in
the long run.
 CONTENT

CERTIFICATE i
ACKNOWLEDGEMENT ii
ABSTRACT iii
CONTENT iv-v
LIST OF FIGURES
LIST OF TABLES
CHAPTER-1 INTRODUCTION
1.1 Cnc work theory
1.2 Classification of Cnc machine
1.3 Coordinate system

CHAPTER-2 COMPANY PRODUCTS

2.1 Turning / Turn mill centre (TMC)
2.2 Vertical machining centre (VMC)
2.3 Horizontal machining centre (HMC)

CHAPTER-3 COMPONENTS OF CNC

3.1 Spindle
3.2 Saddle
3.3 Base
3.4 Linear motion guid ways (LM)
3.5 Pallete
3.6 Automatic tool changer
3.7 Head stock
3.8 Tail stock
3.9 Turret assembly
3.10 Controller
3.11 Pumps
3.12 Motors
3.13 Outer sheet metal body
CHAPTER-4 ASSEMBLY OF CNC MACHINE
CHAPTER-5 TYPES OF CNC PROGRAMING
5.1 Cnc programing element
5.2 Operating mode
5.3 Cnc m/c parts and their functions
5.4 G-codes and their group
5.5 Method of inserting new program

CHAPTER-6 CNC M/C START PROCEDURE

CHAPTER-7 OPERATING PANEL KEY OF CNC LATHE M/C
CHAPTER-8 CNC OPERATING
8.1 Operating panel keys
8.2 Operating mode

CHAPTER-9 CNC SETTING

9.1 Method of making geometric offset

CHAPTER-10 CNC TOOLING

CHAPTER-11 DELCAM
11.1 Feature cam
11.2 Power mill

CHAPTER-12 CONCLUSION
1. REFERENCES
 LIST OF FIGURES

Figure. No. Figure Name Page No.

Block diagram of CNC lathe machine

CNC lathe machine

PLC unit of CNC lathe machine

General sketch of CNC

Pallet

Head Stoke

Tail Stoke

Turret

3-Point levelling

Chuck

Saddle (Model DX-200)

Seven types of operating mode

Method of Geometric Offset

CNC Tooling

Tool Holder Designation System

Turning Operation

Tapering Operation

Pattern Repeating

Treading Operation

Feature Cam Software Interface

Power mill Software Interface

 LIST OF TABLES

Table. No. Table Name Page No.

Plane Selection in CNC lathe machine

CNC machine parts and their function

G – Codes and their group

Tan θ Values

Sin θ Values

Types of Keys of CNC lathe m/c on its Operating panel

Dimension Calculation values for Threading

 INTRODUCTION

Computer Numerical Control (CNC) Machining is the process through which computers
control machine-based processes in manufacturing. The kinds of machines controlled include
lathes, mills, routers and grinders – all used for manufacturing of metal and plastic products.

A CNC machine is a motorized manoeuvrable tool and often a motorized manoeuvrable

platform, which are both controlled by a computer, according to specific input instructions.
Instructions are delivered to a CNC machine in the form of a sequential program of machine
control instructions such as G-code and then executed. The program can be written by a
person or, far more often this century, generated by graphical computer-aided design (CAD)
software. In the case of 3D Printers, the part to be printed is "sliced", before the instructions
(or the program) is generated. 3D printers also use G-Code.

CNC is a vast improvement over non-computerized machining that must be manually

controlled (e.g., using devices such as hand wheels or levers) or mechanically controlled by
pre-fabricated pattern guides (cams). In modern CNC systems, the design of a mechanical
part and its manufacturing program is highly automated. The part's mechanical dimensions
are defined using CAD software, and then translated into manufacturing directives by
computer-aided manufacturing (CAM) software. The resulting directives are transformed (by
"post processor" software) into the specific commands necessary for a particular machine to
produce the component, and then are loaded into the CNC machine.

Since any particular component might require the use of a number of different tools – drills,
saws, etc. – modern machines often combine multiple tools into a single "cell". In other
installations, a number of different machines are used with an external controller and human
or robotic operators that move the component from machine to machine. In either case, the
series of steps needed to produce any part is highly automated and produces a part that
closely matches the original CAD.

1.1 CNC Work Theory

Computer Numerical control (CNC) is used to automate the machine tools that are operated
by precisely programmed commands encoded on a storage medium, as opposed to controlled
manually via hand wheels or levers, or mechanically automated via cams alone.
Computers play an integral part of the control. In modern CNC system computer-aided
design (CAD) and computer-aided manufacturing (CAM) programs are used for
development and machining of the final finished product.

The series of steps needed to produce any part is highly automated and produces a part that
closely matches the original CAD design. Modern CNC mills differ little in concept from the
original model built at MIT in 1952. Mills typically consist of a table that moves in the X and
Y axes, and a tool spindle that moves in the Z (depth).

The position of the tool is driven by motors through a series of step-down gears in order to
provide highly accurate movements, or in modern designs, direct-drive stepper motor or
servo motors. Open-loop control works as long as the forces are kept small enough and
speeds are not too great.

On commercial metalworking machines closed loop controls are standard and required in
order to provide the accuracy, speed, and repeatability demanded.

As the controller hardware evolved, the mills themselves also evolved. One change has been
to enclose the entire mechanism in a large box as a safety measure, often with additional
safety interlocks to ensure the operator is far enough from the working piece for safe
operation.

Most new CNC systems built today are completely electronically controlled. CNC-like
systems are now used for any process that can be described as a series of movements and
operations.

These include laser cutting, welding, friction stir welding, ultrasonic welding, flame and
plasma cutting, bending, spinning, hole-punching, pinning, gluing, fabric cutting, sewing,
tape and fibre placement, routing, picking and placing (PnP), and sawing most CNC
machines use Siemens or Fanuc made control systems.

For Fanuc generally the coding is done using G codes and M codes. G codes are used for
machining operations and movement of the tools whereas M codes are used for controlling
the spindle movement like on/off, rotation in clockwise or anti-clockwise direction and also
for tool change operation.
 Figure 2: - Block Diagram of CNC Lathe

1.2 Coordinate System

Coordinate system is used for getting point to point movement of tool according to
coordinates of points.
Axis: - Horizontal and vertical lines are known as Axis.

Horizontal Axis Vertical Axis

Plane: - A plane has two axes.

+Y

Centre of Origin

-X +X
0

-Y
 Plane selection in CNC: -

Code Plane selection Used

G17 X-Y VMC

G18 X-Z CNC turning

G19 Y-Z HMC

Table 2.2: - Plane Selection in CNC Lathe M/C.

Origin or Centre Point: - It is the point at a plane where value of both axes zero.
Coordinate: - The value of axis at any point of a plane known as coordinate.

Types of Coordinates: -
1. Absolute Coordinate: - The value of any point will be taken with respect to centre point.
2. Incremental Coordinate: - The value of any point will be taken with respect to previous
point.

1.3 Classification of CNC Machine

- CNC is stand for “Computerized Numerical Control”. A machine which is controlled by
computer with Numerical values is known as CNC Machine.
 Turning Machine

+
NC System

NC Machine
+
Computer

CNC Machine

Two Axis
More than Two Axis
(x & z) (x, y, z, a, b, c, ….)

CNC Turning CNC Wire Cut CNC Milling CNC Gri

VMC HMC
(Vertical Machining Centre ) (Horizontal Machining Cene
 COMPONENTS OF CNC

3.1 Spindle
The spindle is directly coupled with the spindle motor refer Figure 4 and
avoids any errors in indirect drive mechanism.

This high speed spindle is specially designed to meet the requirement of

small component machining with high precision and dynamism.

Spindle is having BT-40 and 50Tool, HSK 100 interface taper for VMC
machines.

3.2 Saddle
Saddle is the part of CNC which is mounted on the Linea Motion guide ways (LM).

They provide for the linear motion in either X or Y axis.

3.3 BASE

Base is the base structure of CNC on which the entire operation of CNC is
performed. It is made of rigid structure of Cast Iron because of good compressive
strength and vibrational damping capacity.

3.4 LINEAR MOTION GUIDE WAYS (LM)

Linear motion guide ways or LMs are V or U shaped solid structure mounted
on base for saddle and on saddle for pallet to allow the saddle and pallet to
slide over them linearly along X and Y axis respectively.

3.5 Pallet
 Figure 4.5: - Pallet

Pallet is used to clamp or unclamp job piece. It is mounted on LM which are

mounted on saddle. They are perpendicular to the LM mounted on base.
That is, if one is in X- direction then other one is in Y- direction.

3.6 Automatic Tool Changer

The tool changer is an umbrella type Servo ATC having a 12 Tool magazine.

The tool change time is 3.5 seconds. Its main function is to change the tool
during the machining according to the requirement.

It works with 3 servo motors. One for vertical motion up-down, one for
rotary action about Z-axis and one for clamping and releasing the tool.

3.7 Head Stock

It supports chuck and its mechanism. It possesses system which clamps and
de-clamps of
Work-piece.

Figure 4.7: - Head Stock

4.8 Tail Stock

It possesses the supporting elements. It is also used for supporting the long
job pieces and also used for centring and drilling purpose.
 Figure 4.8: - Tail-Stock

3.9 TURRET ASSEMBLY

It is that part of machine which has tools to work on job. Generally, it has ten to
twelve tools. It is used for holding the tools to carry out machining operations.

Figure 4.9: - Turret

3.10 Controller

It contains Siemens or Fanuc or Heidenhaim controller which controls the

whole machine.

3.11 Pumps
 There are generally two pumps in CNC. One is for hydraulic oil transmission
and another for coolant circulation. Thus pump keeps the cooling and the
lubrication system of the CNC alive.
3.12 Motors

There are many different motors used mainly for revolving of chuck, another
two for bolt screw, revolving of turret, and motion of work table i.e. pallet in
X and Y-axes.

3.13 Outer Sheet Metal Body

It provides safety to user and adds aesthetic value to the machine
 ASSEMBLY OF CNC MACHINE
First step of assembly is to do three point levelling system by spirit level and then
tight the other 3 points. Thus the Base of CNC is fixed on the floor.

Figure 5.1: - 3-Point levelling

Second step is to scrapping the paint from guide-ways for fitting L.M. Then worker
clean the surface by diesel and air cleaner. Then fit the L.M. and it is supported by
eccentric head bolts.

Then worker uses spray-cleaner to remove dust and mounts saddle on it. After that,
he does

“Auto-collimator Test” for measuring allowances for top and side of L.M. Same
process is carried out for L.M. of saddle and then bolt-screw is mounted on
saddle with two bearing and its run-out testing is carried out and then again top
and side of bolt-screw is maintained in tolerance limit with help of dial-gauge
indicator.
Dial gauge indicator is most important testing device for which range is between
2 μm to 10 μm for different purposes.
After that saddle is mounted on CNC bed. Then bolt-screw is mounted on CNC
bed for z-axis. Than the same process is carried out as it is carried out for bolt-
screw of saddle. Then lock-nut is mounted on it.

If surface plate is not accurately machined, scrapping is carried out till it slides
thoroughly on

L.M.

During this process another worker mounts head-stock and tail stock on its base.

After that chuck, pulley, motor and spindle is mounted on head-stock. Then
mandrel is mounted on chuck.

Figure 5.2: - Chuck

Centre line of head-stock and tail-stock must be co-lined, if not then it must
carried out with the help of height-gauge. Then the ATC is mounted and at the
same time all the wirings are connected with the motors and the pumps and then
the entire electrical system is mounted.

After that telescopic cover is mounted on saddle to cover sliding mechanism from
coolant.

After that hydraulic oil system is fitted with its all mountings like oil sump with
nitrogen gas accumulator, solenoid valves, pipe.

Finally, the cold roll coil sheets are used for final guard (from metal chips and from
water-oil coolant). For preventing leakage of coolant, copper stripes are rigidly
fitted with silicone gel.

Then Siemens or Fanuc controller is attached to the machine. Finally, the doors are
fitted so that entire machine remains closed during operation for the safety of the
operators. Chip removal system and cooling fluid system was installed according to
the demand.

Now the machine is started and data is loaded on it.

Some of the CNC machine models are:

VMC -640, DX-250, ATM-160, VMC-430, TM-020, AM-430, TMC-350

Given is an example of DX-200 and DX-250.

i. Complete CNC machine Dx-200 is completely assembled within 6-7 days,

while Dx- 250 takes 8 to 10 days.

ii. Minimum rpm is 1 and maximum rpm can be up to 6000.

iii. Hydraulic power pack is installed (hydraulic pressure up to 70 bar is
generally used).

iv. Hydraulic system used is oil based.

iv. It uses 440V AC source.

v. Has pneumatic pressured air cleaning gun.

vi. For all movement bolt screw is used.

vii. Tool post (turret) can hold up to 24 tools at a time.

viii. Using the Siemens controller operation begins and can prepare most
complicated operation with high accuracy.

Model Dx-250 is also available which is bigger in size than Dx-200, main
difference in assembling method between them is, In Dx-200 saddle is assembled
at inclination keeping base horizontal while in Dx-250 the saddle is assembled
keeping the base inclined at 45degree for assembly ease.

Figure 5.3: - Saddle (Model Dx-200)

 6. TYPES OF CNC PROGRAMING

 CNC Programming is made of blocks & blocks are made by commands. Commands are provided for
different functions.
6.1 CNC Programming Elements: -

I. Command, II. Block,

III. Different Addressing Code, IV. Program Scan,

V. Program Header, VI. Program Footer

I. Command: - Command is the combination of alphabetic character &

numerical value where alphabetic is used for address & numerical is used for
value. Alphabet A to Z, numerical 0-9. Ex - G0 X4 Z2 N1

II. Block: - Group of commands known as block. One block has one or more
commands. Block is started from sequence Number & ended by end of block
command Where sequence no. is optional.

III. Different Addressing Code: -

III.I G – Code: - These are Preparatory function codes & used for
different function.
A. Axis Movement: - G0/G01/G02/G03 codes are used for programming
of any axis.

 Code G00 = This code is used for tool positioning & free movement in air.

Format – G00 X... Z…;

 Code G01 = This code is used for linear movement of axis

Format – G01 X... Z… F…;

 Code G02 = This code is used for circular clock wise movement of any axis.

Format – G02 X... Z… R… F…;

 Code G03 = This code is used for circular anticlockwise movement of any axis.

Format – G03 X... Z… R… F…;

 Code G28 = This code is used for homing of any axis.

Format – G28 U0.0 W0.0;

B. Dwell Time: -

 G04 X…. (time in second)

 G04 U…. (time in second)
 G04 P…. (time in m.s.)

C. Plane Selection: -

 G17 – X-Y plane selection

 G18 – X-Z plane selection
 G19 – Y-Z plane selection

D. Inch./mm Mode Setting: -

 G20 – program in inch.

 G21 – program in mm.

E. Stroke Check Function: -

 G22 – stored Stroke check function On

 G23 - stored Stroke check function Off

F. Reference Return: -

 G27 – reference return check

 G28 – 1st ref. point
 G29 – return from 0 point
 G30 – 2nd ref. point

G. Skip Function: -

 G31 – skip function

H. Thread Cutting: -

 G32 – thread cutting

  G34 – variable lead thread cutting

I. Tool Nose Radius: -

 G40 – Tool nose radius compensation cancel

 G41 - Tool nose radius compensation left
 G42 - Tool nose radius compensation right

J. Coordinate System (50 Series): -

 G50 – coordinate sys. setting or max. spindle rpm.

 G52 – local coordinate system setting
 G53 – machine coordinate system setting
 G54 – work piece coordinate system 1 selection
 G55 – work piece coordinate system 2 selection
 G56 – work piece coordinate system 3 selection
 G57 – work piece coordinate system 4 selection
 G58 – work piece coordinate system 5 selection
 G59 – work piece coordinate system 6 selection

K. Canned cycle (G70 & G80 Series): -

 G70 – finishing cycle of G71, G72 & G73

 G71 - stock removal of turning
 G72 – stock removal of facing
 G73 – pattern repeating
 G74 – end face peck drilling
 G75 – outer diameter / internal diameter drilling
 G76 – multiple threading cycle
 G77 – pocket cutting & turning
 G78 – single threading cycle
 G79 – pocket cutting in facing
 G80 – canned cycle cancel
 L. Mode Setting (G90 Series): -

 G90 – absolute programming

 G91 – incremental programming  G92 – max. spindle rpm 
G94 – feed mm per min.
 G95 – feed mm per revolution
 G96 – constant surface speed control
 G97 – cancellation of G96
 G98 – return to initial point
 G99 – return to r point

III.II M – Code: - These are miscellaneous function codes and it is used for
Start / Stop of any function.

 MO – program stop
 MO1 – program optional stop
 MO2 – program optional end  MO3 – spindle on clock wise
 MO4 – spindle on anti-clock wise
 MO5 – spindle stop
 MO6 – tool changing in VMC
 MO7 – coolant on
 MO8 – coolant on/off
 MO9 – cool off
 M19 – spindle orientation  M30 – program end reset

 Different addressing codes used in CNC: -

 A – extra axis
 B – extra axis
 C – extra axis
 D – cutter diameter in VMC
 F – feed on axis
 G – G code program
 H – tool length offset in VMC
 I – the value of X from start point of radius to center of radius.
 J – the value of Y from start point of radius to center of radius.
 K – the value of X from start point of radius to center of radius.
 L – loop in VMC
 M – m code groups  N – sequence no.
  O – program no.
 P – peak depth in X
 Q – peak depth in Z
 R – radius  S – spindle
 T – tool no. & offset no. in CNC
 U – X axis value in incremental program
 V – Y axis value in incremental program
 W – Z axis value in incremental program
 X – X axis value in absolute program
 Y – Y axis value in absolute program
 Z – Z axis value in absolute program

IV. Program Scan: - CNC M/c Scan the program sequentially in Blocks from
Top block to bottom block.

V. Program Header: -

 Program No.
 Sequence No.
 Cancellation command
 M/c Home position
 Tool & Offset selection
 Spindle R.P.M with direction
 Coolant On
 Tool positioning

VI. Program Footer: -

 Tool return to Home position

 Spindle stop
 Coolant off  Program End & Reset

6.2 Operating Mode: -

1. Manual mode – manual mode is used for individual start / stop of any function.
Different functions:
 Chuck clamp/D clamp – chuck is used for holding the job.
Method –
Step 1 – select jog mode
Step 2 – chuck clamp / D clamp by foot switch

Conditions – all axis should be at home.

Turret index – turret is the tool holding device used for holding the tool &
supporting against cutting force.
Different stations are used for holding different tools 8 station turret is using in this
machine.
Conditions – all axis should be at home.

2. Auto mode – auto is used for automatic running of NC program.

Single block – block by block running program.

Method –
Step 1 – select auto
Step 2 – select single block
Step 3 – press cycle start button -> single block
Will work on pressing one time to the cycle start button for next block repeating
cycle start button.

6.3 CNC Machine parts and their Function: -

OPERATING MODES WITH PROCEDURE
SNO. FUNCTION ACTIVITY JOG HANDLE MDI AUTO/PROG
MAIN on direct direct direct direct
1 SWITCH &
SERVO STAB. off direct direct direct direct
2 on direct direct direct direct
 CNC off direct direct direct direct
on direct direct direct direct
3 HYDRAULIC
off direct direct direct direct
MO3
CW PB NA S1200 ; MO3 S1200 ;
4 SPINDLE MO4
CCW PB NA S…….. ; MO4 S…….. ;
stop PB NA MO5 ; MO5 ;
on PB NA MO7 ; MO7 ;
5 COOLENT
off PB NA M09 ; M09 ;
clamp foot switch NA M10 ; M10 ;
6 CHUCK
D clamp foot switch NA M11 ; M11 ;
TURRET PB NA T0202 ; T0202 ;
7 INDEX Note : Turret index will be possible when X & Z
are at home
GO X…..
+ Z……; GO X….. Z……;
-
Select JOG
Select AXIS Select handle
then (+) or (-) select (X) or (Z)
speed control by select speed
8 X AXIS feed override [X1], [X10],
[X100]
move MPG
speed control
depends on
handle rotate &
speed select
select reference
return mode
press [X]
press [+]
REFERENCE press [Z]
9
RETURN press [+]

Note : Speed control will be done by feed

override
FORWORD foot switch NA M27 M27
10 TAIL STOCK
REVERSE foot switch NA M28 M28
NOTE : Do not use JOG mode for X Axis & Z Axis travel
Table 6.3: - CNC machine parts and their function
6.4 Some G – codes and their Group: -
G CODE SYSTEM GROUP FUNCTION
A B C
G00 G00 G00 Positioning (Rapid Travels)
G01 G01 G01 Linear interpolation (cutting Feed)
01
G02 G02 G02 Circular interpolation CW
G03 G03 G03 Circular interpolation CCW
G04 G04 G04 Dwell
G10 G10 G10 00 Programmable data input
G11 G11 G11 Programmable data input cancel+E30
G18 G18 G18 16 ZpXp plane selection
G20 G20 G70 Input in inch
06
G21 G21 G21 Input in inch
G22 G22 G22 Stored stroke check function on
09
G23 G23 G23 Stored stroke check function on
G27 G27 G27 Reference position return check
G28 G28 G28 Return to reference position
00
G30 G30 G30 2nd,3rd & 4th reference position return
G31 G31 G31 Skip function
G32 G33 G33 Thread cutting
01
G34 G34 G34 Variable-lead thread cutting
G40 G40 G40 Tool nose radius compensation cancel
G41 G41 G41 07 Tool nose radius compensation left
G42 G42 G42 Tool nose radius compensation right
Coordinate system setting or max spindle
G50 G92 G92 00 speed setting
G50.3 G92.1 G92.1 Work piece coordinate system preset
G52 G52 G52 Local coordinate system setting
00
G53 G53 G53 Machine coordinate system setting
G54 G54 G54 Work piece coordinate system 1 selection
G55 G55 G55 Work piece coordinate system 2 selection
G56 G56 G56 Work piece coordinate system 3 selection
14
G57 G57 G57 Work piece coordinate system 4 selection
G58 G58 G58 Work piece coordinate system 5 selection
G59 G59 G59 Work piece coordinate system 6 selection
G65 G65 G65 00 Macro calling
G66 G66 G66 Macro model call
12
G67 G67 G67 Macro model call cancel
G70 G70 G72 00 Finishing cycle
G71 G71 G73 Stock removal in turning
G72 G72 G74 Stock removal in facing
G73 G73 G75 Pattern repeating
G74 G74 G76 End face peck drilling
G75 G75 G77 Outer diameter / internal diameter drilling
G76 G76 G78 Multiple threading cycle
Outer diameter / internal diameter cutting
G90 G77 G20 cycle
G92 G78 G21 01 Thread cutting cycle
G94 G79 G24 End face turning cycle
G96 G96 G96 Constant surface speed control
02
G97 G97 G97 constant surface speed control cancel
G98 G94 G94 Per minute feed
05
G99 G95 G95 Per revolution feed
G90 G90 Absolute programming
03
G91 G91 Incremental programming
G93 G98 Return to initial level
11
G99 G99 Return to R point level
Table 6.4: - G – Codes & their Group