Air University

Institute of Avionics and Aeronautics

Department of Mechanical and Aerospace Engineering

LAB REPORT MP-II LAB

➢ Group Members:
12/12/2024
• Abdul Wahid 220923
• Mubashir 220887
• Osama Sattar 220844
• Sheikh Atazaz 220868
• Haseeb Sajid 220893

➢ Submitted To:

• Engr. Sarmad Fayyaz

 Manfacturing Lab Report

Table of Contents:
1. Objectives of CNC Milling Machines………………………………………………………3
2. Introduction to CNC Milling Machines……………………………………………………..4
3. Applications of CNC Milling Machines……………………………………………………...5
4. Safety precautions of CNC Milling…………………………………………………………..7
5. Lab Task with Complete Procedure and Code……………………………………………..…11
6. Word Distribution……………………………………………………………………………16
7. References…………………………………………………………………………………………..17
Manfacturing Lab Report
1. Objectives of CNC Milling Machines:
The primary objectives of CNC milling machines are:
a. To Machine Complex Parts:
CNC milling machines are used to machine complex parts with high accuracy and precision,
including parts with intricate shapes, profiles, and features.

b. To Increase Productivity:
CNC milling machines are designed to increase productivity by automating the machining process,
reducing labor costs, and improving efficiency.

c. To Improve Product Quality:

CNC milling machines are used to improve product quality by ensuring high accuracy and precision,
reducing errors, and improving surface finish.

d. To Reduce Labor Costs:

CNC milling machines are designed to reduce labor costs by automating the machining process,
reducing the need for manual labor, and improving efficiency.

e. To Increase Flexibility:
CNC milling machines are used to increase flexibility by allowing for quick changes in production,
reducing setup times, and improving adaptability to changing production requirements.

1
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2. Introduction to CNC Milling Machines:

A Computer Numerical Control (CNC) milling machine is a computer-controlled machine tool that
uses a rotating cutting tool to remove material from a workpiece. The machine is equipped with a spindle
that holds the cutting tool, and a table that moves in the X, Y, and Z axes to position the workpiece under the
cutting tool. CNC milling machines are widely used in various industries, including aerospace, automotive,
medical, and consumer products, to machine complex parts with high accuracy and precision. The use of
CNC milling machines has revolutionized the manufacturing industry by increasing productivity, reducing
labor costs, and improving product quality.

2.1 Tasks Performed on a CNC Milling Machine:

2.1.1 G and M Coding:
The machine uses G and M codes to perform various operations, including:
• G codes: used to control the movement of the machine, such as G00 (rapid positioning), G01 (linear
interpolation), G02 (clockwise circular interpolation), and G03 (counter-clockwise circular
interpolation)
• M codes: used to control the machine's functions, such as M03 (spindle clockwise), M04 (spindle
counter-clockwise), and M06 (tool change)
1. Centring: The machine can perform centring operations to create a center hole or a center mark on a
workpiece.
2. Pocketing: The machine can perform pocketing operations to create a pocket or a cavity in a
workpiece, including:
• Circular Pocketing: used to create a circular pocket or cavity

• Rectangular Pocketing: used to create a rectangular pocket or cavity

3. Drilling: The machine can perform drilling operations to create holes in a workpiece.
4. Milling: The machine can perform milling operations to remove material from a workpiece and create
complex shapes and profiles.
5. Tapping: The machine can perform tapping operations to create threaded holes in a workpiece.
6. Boring: The machine can perform boring operations to enlarge existing holes in a workpiece.
7. Facing: The machine can perform facing operations to create a flat surface on a workpiece.
8. Chamfering: The machine can perform chamfering operations to create a beveled edge on a
workpiece.
9. Deburring: The machine can perform deburring operations to remove burrs and sharp edges from a
workpiece.

➢ Lab Performance:
In this lab session, we focused on leveraging the capabilities of a CNC milling machine by performing
tasks such as shape creation, pocket drilling, and engraving text. These exercises aimed to build practical
knowledge of CNC programming, machining strategies, and operational safety.
In this lab session, we explored the capabilities of a CNC milling machine through four practical tasks:
creating basic shapes, adding features, and engraving text. These tasks were designed to enhance our
understanding of CNC programming, tool selection, and machining parameters.
 Manfacturing Lab Report

3. Applications of CNC Milling Machines:

CNC milling machines are widely used in mechanical engineering for various applications, including:
a. Design and Prototyping: Creating Prototypes and Models
CNC milling machines are used to create prototypes and models of mechanical components, allowing
engineers to test and evaluate their designs before moving to production.
➢ Examples:
• Creating a prototype of a new engine block design to test its performance and durability.
• Designing and testing a new gearbox component to improve transmission efficiency.
3.2 Manufacturing and Production: Mass Producing Mechanical Components
CNC milling machines are used to manufacture mechanical components in large quantities, with high
precision and accuracy.
➢ Examples:
• Producing engine blocks and cylinder heads for a major automotive manufacturer.
• Manufacturing transmission cases and gearboxes for a leading aerospace company.
3.3 Research and Development: Testing and Evaluating New Technologies
CNC milling machines are used to test and evaluate new materials, technologies, and designs, allowing
engineers to develop and improve their products.
➢ Examples:
• Testing the performance of a new advanced composite material for aerospace applications.
• Developing and testing a new electric motor design for hybrid vehicles.
3.4 Maintenance and Repair:
CNC milling machines are used to repair and rebuild mechanical components, extending their lifespan
and reducing waste.
➢ Examples:
• Rebuilding a damaged engine block for a heavy-duty truck.
• Repairing a faulty transmission case for a high-performance sports car.
3.5 Aerospace and Defense: Manufacturing Critical Components
CNC milling machines are used to manufacture critical components for aerospace and defense
applications, requiring high precision and accuracy.
➢ Examples:
• Producing aircraft engine components, such as turbine blades and compressor blades.
• Manufacturing missile guidance systems and control components.
 Manfacturing Lab Report

4. Safety precautions of CNC Milling:

• Proper Training: Ensure the operator is properly trained on CNC machine operation and safety
protocols.
• Personal Protective Equipment (PPE): Wear appropriate safety gear such as safety glasses,
hearing protection, gloves, and steel-toed boots.
• Machine Setup: Verify the machine is correctly set up before use, ensuring proper calibration, tool
installation, and workpiece positioning.
• Tool Inspection: Regularly check the condition of milling tools for wear or damage, and replace
them as needed.
• Machine Maintenance: Follow the manufacturer’s maintenance schedule for regular cleaning,
lubrication, and inspection of the machine.
• Clear Work Area: Keep the work area clean and free of obstructions to prevent accidents or
interference with machine operation.
• Correct Workholding: Use proper fixturing or clamping methods to securely hold the workpiece
in place during milling.
• Feed Rate and Speed: Set the correct feed rate, spindle speed, and cutting parameters according to
material and tool requirements.
• Avoid Overloading: Do not exceed the machine's maximum load or cutting capacity, which can
lead to tool damage or machine failure.
• Monitor Machine Operation: Continuously observe the machine while it is running, being ready
to stop it in case of an emergency.
• Electrical Safety: Ensure that electrical connections are properly insulated and grounded, and
check for exposed wires.
• Coolant Management: Use coolant properly to reduce heat buildup and prevent tool wear, and
ensure proper disposal of used coolant.
• Emergency Stops: Familiarize yourself with emergency stop procedures and ensure that the
emergency stop buttons are accessible at all times.
• No Loose Clothing or Jewelry: Avoid wearing loose clothing, ties, or jewelry that could become
caught in the machinery.
• Avoid Distractions: Stay focused while operating the CNC machine, and avoid distractions that
could lead to mistakes or accidents.
• Documentation: Maintain and follow all machine operation manuals, safety guidelines, and
technical documentation for specific operations.
 Manfacturing Lab Report

5. Lab Task with Complete Procedure and Code:

Task 1: Machining a Rectangle

➢ Required Part:

➢ Procedure for Cutting a Rectangular Plate on a CNC Milling Machine

• Workpiece Preparation and Tool Selection
The workpiece is secured to the machine bed using clamps to prevent movement during
machining. A flat end mill is selected as the cutting tool to create straight edges and smooth surfaces.
• Programming the Machining Operation
The G-code is written to define the rectangle dimensions (15 mm x 25 mm) and tool paths. The
cutting parameters, including spindle speed, feed rate, and depth of cut, are set to achieve the desired finish
and accuracy.
 Manfacturing Lab Report

• Executing the Machining Process

The toolpath simulation is verified to ensure accurate cutting, and the program is executed to
machine the rectangle. The machining process is monitored to ensure precise dimensions and smooth edges
are achieved.
➢ Code:
G54 G19 G91 G71
M03 S2500
G00 X5
Y5
G01 Z-1
X15
Y25
X-15
Y-25
Z1
G00 X0
Y0
M30

Task 2: Creating a Square with Semicircles and Fillets

➢ Required Part:
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➢ Procedure for Machining a Square with Semicircles and Fillets

• Material and Tool Preparation
A square blank is selected as the base material, and an end mill suitable for machining fillets
and arcs is chosen. This ensures that the desired features can be accurately created.

• Design and Programming

A square shape with two semicircles on opposite sides is created using arc commands
(G02/G03). Fillets are programmed at all edges to produce rounded corners, and a central hole
is drilled using a drill bit with a radius of 5 mm. This stage involves careful planning to ensure
that the design is accurate and complete.

• Machining and Verification

The toolpath is simulated to verify the design accuracy and ensure that the program is correct.
Once verified, the program is executed to produce the square with the desired features,
including semicircles, fillets, and a central hole.

➢ Code:
G54 G71 G19 G90
M03 S2500
G00 X5
Y5
G01 Y20
G02 X5 Y24 R9
G01 Y32.5
X15
G02 X25 Y32.5 R5
G01 X27.5
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G03 X32.5 Y27.5 R5

G01 X5
Y5
G00 Z1
X20
Y7.5
G01 Z0
G03 X20 Y12.5 R5
G00 Z1
X-5 Y-5
By using Drill:
Following change is to be made:
M06
T02 (Drill bit of radius 5)
G00 X25 Y12.5
G01 Z-1
G00 Z1
X-5 Y-5
M30

Task 3: Drilling Circular Pockets

➢ Required part:
 Manfacturing Lab Report

➢ Procedure of Machining Circular Pockets:

• Workpiece Setup
A rectangular plate is clamped securely to the machine bed to prevent movement during
machining. A suitable drill bit is selected for creating pockets, ensuring accurate and efficient machining.
• Pocket Design and Programming
The positions and depths of five circular pockets are defined, evenly distributed across the
rectangle. A pocketing cycle command (G81/G83) is used in the G-code to efficiently create the pockets,
minimizing machining time and ensuring consistent results.
• Machining the Pockets
The G-code is verified, and the toolpaths are simulated to ensure accuracy. The pockets are then
drilled sequentially, achieving consistent depths and clean edges.

➢ Code:
G54 G17 G90 G71
T01
M03
G00 X0 Y0
G01 X100 Y0
G01 X100
Y100
G01 X0
Y0
T01
G01 Z0.05
G01 X25 Y25
G01 Z-10
G00 Z0.05
G00 X25 Y75
G01 Z-10
G00 Z0.05
G00 X50 Y50
G01 Z-10
G00 Z0.05
G00 X75 Y25
 Manfacturing Lab Report

G01 Z-10
G00 Z0.05
G00 X75 Y75
G01 Z-10
G00 Z0.05
G00 X0 Y0
M30
Task 4: Engraving the "OSM"
➢ Required part:
 Manfacturing Lab Report

➢ Procedure for Engraving the "OSM"

• Subprogram Implementation:
Designed the text "OSM" in G-code using subprograms for repeated letter patterns. Assigned
toolpaths for each character, ensuring proper alignment and spacing.
• Engraving Process:
Adjusted the spindle speed and feed rate for engraving depth and clarity. • Ran the program to
engrave the text with consistent quality.
• Verification and Finishing:
Inspected the engraving for alignment, depth, and legibility. • Performed deburring to remove
any sharp edges or burrs from the engraved text.

➢ Code
Main Program:
G90 G71 G94 G54
T01D1
M03 S700
G00 X10 Y10
Z5
L10
Z2
G00 X30 Y10
Z-5 F100
L20
Z2
G00 X50 Y10
Z-5 F100
L30
Z2
Z50 F500
M30
Sub Program:
L10
N10 G01 X10 F250
N20 G01 Y20
N30 G01 X-10
N40 G01 Y-20
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N50 G90
N60 M17
L20
N10 G91
N20 G01 Y20
N30 G01 X5 Y-10
N40 G01 X5 Y10
N50 G01 Y-20
N60 G90
N70 M17
L30
N10 G91
N20 G01 X10 F250
N30 G01 Y10
N40 G01 X-10
N50 G01 Y10
N60 G90
N70 M17
 Manfacturing Lab Report

6. Word Distribution:
➢ 2D Design and Making:
Making of part on SolidWorks with dimensions was done by Osama Sattar and Atazaz.
➢ Code Writing:
Code Writing was performed and written by Abdul Wahid and Haseeb Sajid.
➢ Lab Report:
Lab report was Compiled and completed by M. Mubashir and Abdul Wahid.
➢ Manufacturing at Machine:
The parts manufacturing at the CNC milling machine was done by the whole group .

7. References:

1. The information about the procedures and the Code purpose was given by Engineer’s
(Sir Sarmad Fayyaz and Sir Haseem Umer)
2. 2nd and 3rd codes were checked by Sir Haseen Umer
3. All the practical work on the CNC Milling Machine was done under supervision by Sir Abid
Qayyum Khan
4. The Codes syntax was given through the CNC Programming Handbook provided by Sir Sarmad
Fayyaz