Faculty

: Facultty of Engineering and Science Course : Bachelor of Engineering (Hons) Mechanical, Mechatronics, Materials and Manufacturing Engineering Year/Semester : Year 1 Semester 2 Session : Jan 13

Unit Code Unit Title

: :

UEME1233 Manufacturing Technology 1

Lecturer

Ms Carine Ng Tan Ching

Student 1. 2. 3. 4. Ong Eu-Jeen 5.Jonathan Robert Tsen Tze Kian TITLE: CNC Machining PURPOSE

Student ID

Course

1206811 1206100

Mechatronics (MH) Mechatronics (MH)

To code and interpret the use of Computer Number Control (CNC) Machining language. OBJECTIVE From the machining operations demonstrated by the technician, the objective of this report is to understand and interpret the machine codes that are being inserted into the system to perform an action in the machine. INTRODUCTION Computer Number Control or CNC is machine tools that produce products without direct human assistance. Codes are being inserted into an internal computer and the actions are carried out based on the codes that are being inserted. The CNC machine is very useful in the manufacturing industry due to its high precision and efficiency in producing a finished product. Codes that are used in the experiment can be divided into several parts namely Gcodes, M-codes and other letter addresses. Function of these codes is an instruction as to how the machines should operate following the line of codes that is being inserted. Below are some examples of the codes, Codes G00 G01 G02 G03 Interpretation Rapid positioning Linear interpolation Circular interpolation (clockwise) Circular interpolation (counter clockwise)

G28 M05 M30

Return to reference point Stop spindle End of program

Of course, there are more codes that are inserted into the internal computer of the machine when carrying out a manufacturing process. For example, Codes X Y F R W Z U Interpretation Specific position or coordinate along X-axis Specific position or coordinate along Y-axis Feed rate during cutting operation Indicating the radius of the arc Incremental in Z-axis Specific position or coordinate along Z-axis Incremental in X-axis

By understanding what these codes represent, we are able to determine the action that is being taken by the machines during the manufacturing process of a product.

APPARATUS 1. CNC Machine 2. Workpiece 3. Code programmer RESULT

Z-axis

X-axis

Codes G28 U0 W0 G00 X-1 Z2 G01 Z0 X0 X3 Z-1.5 F25

Z-3 X4.5 G03 X6 W-0.75 R0.75

G01 Z-6.5 X4 W-1 F25

Z-9 X15 F25 G01 X16 W-0.5 G01 Z-14 X9 Z-20 Z-21 X16 Z-25 Z-27 G03 X15.5 W-0.6 R0.75

G02 X16 Z-45 R17

G03 X18 W-4 R3

G03 X20 W-4 R3

G03 X22 W-4 R3

Interpretation Immediately returns to reference point Rapid movement to position X=-1 along X-axis and Z=2 along the Z-axis Feed tool with linear interpolation to Z=0 Tool is moved to X=0 along the X-axis Tool is moved to X=3 along the X-axis and Z=-1.5 along the Z-axis with a feed rate of 25mm per revolution Tool is moved to Z= -3 along the Z-axis Tool is moved to X= 4.5 along the X-axis Counter clockwise circular interpolation with a radius of 0.75mm to X=6 along the X-axis with incremental of -0.75 mm along the Z-axis Feed tool is moved to Z=-6.5 with linear interpolation Tool is moved to X=4 along the X-axis with an incremental of -1mm along the Z-axis with a feed rate of 25mm per revolution Tool is moved to Z=-9 along the Z-axis Move tool to X=15 along the X-axis with a feed rate of 25mm per revolution Linear interpolation to X=16 with an incremental of 0.5mm along the Z-axis Feed tool is moved to Z= -14 with linear interpolation Tools is moved to X=9 along the X-axis and Z= -20 along the Z-axis Tool is moved to Z=-21 along the Z-axis Tool is moved to X=16 along the X-axis and Z=-25 along the Z-axis Tool is moved to Z=-27 along the Z-axis Counter clockwise circular interpolation with a radius of 0.75mm to position X=15.5 along the X-axis with an incremental of -0.6mm along the Z-axis Clockwise circular interpolation with a radius of 17mm to position X=16 along the X-axis and Z=-45 along the Z-axis Counter clockwise circular interpolation with a radius of 3mm to position X=18 with an incremental of 4mm along the X-axis Counter clockwise circular interpolation with a radius of 3mm to position X=20 along the X-axis with an incremental value of -4mm along the Z-axis Counter clockwise circular interpolation with a radius of 3mm to position X=22 along the X-axis with an incremental of -4 mm along the Z-axis

G01 X23 G03 X25 W-1 R1

G01 X31 Z-65.4 X29 Z-45 X27 G01 Z-65.4 X33 F25 G00 X33 G28 U0 W0 M05 M38 M64 M30 DISCUSSION

Feed tool is moved to X=23 with linear interpolation Counter clockwise circular interpolation with a radius of 1mm to position X=25 along the X-axis with an incremental value of -1mm along the Z-axis Feed tool is moved to X=31 with linear interpolation Tool is moved to Z=-65.4 along the Z-axis Tool is moved to X=29 along the X-axis Tool is moved to Z=-45 along the Z-axis Tool is moved to X=27 along the X-axis Feed tool is moved to Z=-65.4 with linear interpolation Tool is moved to X=33 along the X-axis with feed rate of 25mm per revolution Rapid positioning to X=33 along the X-axis Automatic return to reference point and spindle is offed. Door is opened Set auxiliary output 1 off CNC programming is terminated and restarted.

Throughout the experiment, we observed the chess piece being made by the CNC machine which is controlled by the lab officer by inputting a series of codes into the system and we are asked to interpret these codes. From the experiment, we can see how effortlessly a chess piece could be produced. The workpiece is being held at the axis and the machines will cut the workpiece based on the codes that are being input into the system. The machine has a high level of accuracy in its measurement and cutting which is to say that the product that is produced by these machines is exactly alike and with the help of rotating the workpiece while cutting it, the workpiece formed will be a symmetrical product. The product being produced by these machines can be replicated for hundreds and thousands of times without much error which is to say that the products produced are exactly alike as long as the codes provided are correct and the cutting tools are not wear. In addition, with such accuracy and precision, in the manufacturing industry, percentage of defect products can be greatly reduced thus saving manufacturing costs. In addition, since the workpiece is able to be completed in a short amount of time means that more product can be produced in a daily basis. If the demand for the product increases, with CNC machine, the demand for the product can be meet. CNC machines can also be programmed by advanced designing software that is able to manufacture products that could not be made by manual machines. Designers are able to manufacture their ideas of a product without investing lots of money and time to create a prototype.

Furthermore, CNC machine does not need much supervision by human. The machine can be left to do its work by itself once all the program codes are inserted into the machine. The machine will then interpret these codes line by line as an instruction of what it should do next just like how a person is given instructions to complete a certain task and the person completes the task by following the instructions to the letter. That is how these codes work for the CNC machine. Therefore, the products produced are exactly the same. However, no matter how precise and accurate the product that is being produced by the machine can be, if each component were to be studied thoroughly there will still be a slight difference between them. Nonetheless, the objects are almost identical.

However, the shortcomings of CNC machining is that it depends on the codes to operate so if there is a mistake in the codes that is being input into the system, the product produced will be wrong and. In the manufacturing industry, it will only increase the cost of production due to defect products that are not able to be marketed. Due to the numerous codes that are available, mistakes in the codes' meaning are unavoidable,so it is best to double check the codes before commencing with the manufacturing process to avoid unwanted costs. For example, G00 means rapid positioning while M00 means program stops, so by implementing the wrong codes into the system, the product produced would not be what we expected it to be. Precaution taken during this experiment is that since the cutting of the work piece is carried out when the workpiece is rotating at a very high speed, it will generate a lot of heat from the friction between the workpiece and the cutting tools. Therefore, the workpiece should be handled with care when it is done cutting as to avoid unnecessary accidents.

CONCLUSION The CNC machine is able to produce products which are almost identical to others by simply inputting codes into the machine as instruction of how to cut the object. It does not require much human effort and supervision and saves cost and time. The end product also has a higher precision compared to products that are being manufactured by traditional means (manual machine). In a nutshell, though the codes for CNC machine might be complicated at times but it is designed in such a way that precised and accurate products could be made with percentage of error near to zero. By knowing what these codes represent, it will definitely help us in manufacturing a product using a CNC machine in the near future.