MACHINING WORKSHOP REPORT
DJJ40142 MECHANICAL WORKSHOP PRACTICE 4
TITLE: CNC MACHINING (CNC– TURNING)
NAME: BONG ZHI WU
MATRIX NUM: 11DKM22F1010
CLASS: DKM4B
LECTURER NAME:
a) EN. ISHAK BIN IBRAHIM @ YEM
b) EN. HUSSEIN BIN MD ZAN
SUBMISSION DATE: 18/4/2024
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TABLE OF CONTENTS
1.0 OBJECTIVE.......................................................................................................................3
2.0 INTRODUCTION..............................................................................................................3
2.1 CNC Lathe Machine / Turning Machine.............................................................3
2.2 CNC Turning..........................................................................................................3
2.2.1 Advantages...............................................................................................4
2.2.2 Disadvantages..........................................................................................4
3.0 CNC TURNING EQUIPMENT........................................................................................5
3.1 Parts and Components for CNC Turning Machine............................................5
3.2 List of Tools and Equipment.................................................................................7
4.0 SAFETY PROCEDURE....................................................................................................8
5.0 PROCEDURES..................................................................................................................9
6.0 RESULT............................................................................................................................15
7.0 DISCUSSION...................................................................................................................15
8.0 CONCLUSION.................................................................................................................15
9.0 REFERENCES.................................................................................................................16
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1.0 OBJECTIVE
a) To gain experience and knowledge using the CNC Turning Machine.
b) To learn the CNC Programming Languages. (G-Code and M-Code)
c) To perform the procedure for the CNC Turning Machine based on the drawing.
d) To perform the machining process for the CNC Turning Machine.
2.0 INTRODUCTION
2.1 CNC Lathe Machine / Turning Machine
A CNC lathe machine, also known simply as a CNC lathe or a CNC turning machine,
is a type of computer-controlled machine tool used in manufacturing processes to
shape cylindrical workpieces. It operates by rotating the workpiece while a cutting
tool removes material to create the desired shape. CNC lathe machines are controlled
by computer programs that dictate the movements and operations of the cutting tool.
2.2 CNC Turning
CNC turning is a highly precise and efficient subtractive machining process that
works on the principle of the lathe machine. It involves placing the cutting tool
against a turning workpiece to remove materials and give the desired shape. The
turning center or lathe stays secured while the raw material rotates at high speed. As
the workpiece rotates along a dual CNC turning machine axis movement, a single
point cutting tool helps to shape the material. Computer programs help to control the
turning center or lathe, ensuring the production of meticulously precise components.
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2.2.1 Advantages
a) Precision: CNC turning machines can produce highly precise components
consistently, meeting tight tolerances and specifications.
b) Automation: Once programmed, CNC turning machines can operate
autonomously, reducing the need for manual intervention and labor, leading to
increased productivity and cost-effectiveness.
c) Efficiency (Faster Result): CNC turning machines can operate at high speeds,
leading to faster production times and shorter lead times for manufactured
parts.
d) Complexity: They can produce intricate parts with complex geometries,
including features such as threads, tapers, and contoured surfaces, allowing for
the manufacturing of highly sophisticated components.
e) Consistency: CNC turning machines can produce identical parts repeatedly
without variation, ensuring consistency in quality and performance.
2.2.2 Disadvantages
a) Initial Cost: The initial investment required for purchasing and setting up a
CNC turning machine can be high, especially for advanced models with
additional features and capabilities.
b) Programming Complexity: Programming CNC turning machines requires
specialized knowledge and skills in computer-aided design (CAD) and
computer-aided manufacturing (CAM), which can be challenging for
operators without adequate training and experience.
c) Maintenance Requirements: CNC turning machines require regular
maintenance to ensure optimal performance and longevity, including routine
servicing of components such as spindle bearings, tool holders, and ball
screws.
d) Tooling Costs: The cost of tooling for CNC turning machines, including
cutting inserts, tool holders, and fixtures, can add up, particularly for complex
machining operations and materials with high hardness or abrasiveness.
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e) Risk of Downtime: Any malfunction or breakdown of critical components in
a CNC turning machine can lead to costly downtime and production delays,
highlighting the importance of preventive maintenance and prompt repairs.
3.0 CNC TURNING EQUIPMENT
3.1 Parts and Components for CNC Turning Machine
a) Bed: Provides a rigid base for supporting all other components of
the machine.
b) Headstock: Contains the main spindle, which rotates the
workpiece during machining.
c) Spindle: Rotating shaft that holds and spins the workpiece.
d) Chuck: Device for clamping and securing the workpiece to the
spindle.
e) Tailstock: Supports the opposite end of the workpiece, providing
stability and preventing deflection during machining.
f) Tool turret: Holds multiple cutting tools and indexes or rotates
them into position as needed for machining operations.
g) Tool holders: Secure cutting tools in the tool turret.
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h) Control panel: Interface for programming the machine, setting
parameters, and monitoring operations.
i) CNC controller: Electronic unit that interprets programming
instructions and controls the movements and actions of the
machine.
j) Coolant system: Delivers coolant to the cutting zone to lubricate
and cool the cutting tool and workpiece.
k) Power supply: Provides electrical power to the machine
components.
l) Stabilizer: Control the electricity.
m) Spindle motor: Drives the spindle and rotates the workpiece.
n) Servo motors: Provide precise positioning and movement of
various machine components.
o) Chip Guard Door: providing protection against flying chips,
coolant spray, and other hazards associated with machining
operations.
p) Hydraulic Oil Tank: Provide power for clamping the workpiece,
tool changes, turret indexing, and other auxiliary functions.
q) Lubrication Oil Tank: Deliver lubrication oil and providing
lubrication to various moving parts within the machine.
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3.2 List of Tools and Equipment
Stock (Workpiece) Scraper
Vernier Caliper Safety Goggle
Chuck Key Brush
r)
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4.0 SAFETY PROCEDURE
a) Wearing safety shoes and appropriate attire before entering the workshop.
b) Don’t wear rings, watches, bracelets, or other jewellery that could get caught in
moving machinery.
c) Obey safety rules.
d) Use the safety goggles while operating CNC Turning Machine.
e) Listen and follow the lecturer’s instructions carefully.
f) Follow all written and verbal instructions carefully when using a machine.
g) Read all machine procedures thoroughly before use it.
h) Report any accident or injury to instructor or lecturer immediately, no matter how
trivial it seems. Do not panic.
i) Don’t rest against the machine.
j) Stop the machine immediately if an odd noise or excessive vibration occurs.
k) Secure the work piece tightly in the fixture.
l) Ensure that the tools are tightly fixed in the tool holder.
m) Close the safety guards during machine operation.
n) Use the simulation to avoid machining errors.
o) Do not clean the machine or its attachment when the machine is in operating
condition.
p) Do not operate the machine when the control box is opened.
q) Switch OFF the isolator before opening the electrical cabinet.
r) Do not attempt to clean the machine or remove the swarf when the machine is in
operating condition.
s) Press the emergency stop, on the front of the machine, to cut the power supply to the
spindle and the axes drives, during emergency.
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5.0 PROCEDURES
STEP PROCEDURE
1 Turn on the main power switch and the isolator switch of the machine. After that,
press the CNC ON button at the control panel.
2 Press the Program Manager on the control panel and create new G-code program
(Part programs). My new program file is named BONG_F1010.
3 Press the Various Button on the control panel. Then, press the Blank button and
input the value of the stock size. (CYLINDER,192, 0, -70, -50, 35)
4 Type the commands code as picture shown below with numeric keyboard.
Remark:
G71: MM Programming S: RPM
G95: Feed Rate in mm per revolution T: Tool Call
M06: ATC/ Tool Change D: Tool Diameter
M03: Spindle Clockwise M08: Coolant ON
G00: Rapid Move
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5 Press the Cont. Turn Button on the control panel. Then, press the Contour
button, followed by the Contour coil button. I named the contour with BONG.
6 On the same tab (Cont. Turn), press the Stock Removal button. Add the program
name and insert the value as shown as picture below.
7 On the same tab (Cont. Turn), press the Contour button, followed by the New
Contour button. I named the contour same as previous. Next, insert the value for
the first starting point (X16 Z0) and press Accept for the next movement.
8 Based on drawing, next movement should be Straight ZX. Then, press the
icon button and insert value (X20 Z-2) for the movement.
9 Press the icon button and insert the value (Z-17) for the Straight-line Z
movement and press Accept for the next movement.
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10 Press the icon button and insert the value (R2 X24 Z-19) for the Circle
movement and choose the dialog as shown as picture below.
11 Press the icon button and insert the value (Z-31) for the Straight-line Z
movement and press Accept for the next movement.
12 Press the icon button and insert value (X32 Z-39) for the Straight ZX
movement and press Accept for the next movement.
13 Press the icon button and insert the value (Z-45) for the Straight-line Z
movement and press Accept.
14 Press the Simulation Button on the control panel and run the simulation process.
Simulation process is required to check and make sure the upcoming machining
process is correct.
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15 Add the new command code for the grooving operation (G75 X0 Z0, M06 T7 D1,
M03 S1500, G00 X21 Z-17).
16 Press the Turning Button on the control panel. Then, press the Groove button and
insert the value as shown as picture below.
17 Run the simulation process again to make sure the upcoming machining process is
correct.
18 Add the new command code for the threading operation (G75 X0 Z0, M06 T3 D1,
M03 S500, G00 X20 Z2).
19 On the Turning Tab, press the Thread button and insert the value as shown as
picture below for Thread Longitudinal Movement.
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20 Run the simulation process to check and make sure all machining process is
correct.
21 Lastly, add the new command code for the final programming (G75 X0 Z0, M05,
M09, M30).
Remark:
M05: Spindle Stop
M09: Coolant OFF
M30: Program End
22 Clamp the stock (workpiece) in the chuck and lock the chuck with the chuck key.
23 Offset process for the workpiece origin with coordinate (0,0). Press the MDA
(Manual Data Input) button on the control panel for changing the cutting tool to
Tool 1.
24 Press the MPG (Manual Path Generator) button on the control panel. Next, use
the manual handwheel to adjust and positioning the cutting tool with the stock. We
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are using the paper method for positioning the X and Z axis.
25 Positioning the coolant on top of the workpiece and closing the guard door.
Finally, press the following button (Program> Execute> Auto > Start) on the
control panel to start the machining process.
26 Wait for the machining process to be complete.
27 When the machining process is complete, stop the program and turn off the
machine. Clean the machine and the work area from chips, coolant, or other debris
and properly store the tools and equipment.
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6.0 RESULT
7.0 DISCUSSION
Requirements based on the drawing have been achieved. All the dimensions and lengths of
the workpiece have been measured using the Vernier Caliper. The time for cutting needed is
8 minutes and the time for workpiece setup is around 5 minutes. The machining process
should be done in 15 minutes (excluding the programming process).
8.0 CONCLUSION
From this task, the objectives have been achieved as we have applied safety procedures while
operating the CNC Turning Machine and performing the machining operation. Students need
to follow the steps and instructions shown by the lecturer to ensure that the project can be
completed. Moreover, we must abide by the safety regulations. Cooperation between the
team members is also important to complete this task. This project is meaningful and assists
students in completing the other workshop tasks or final year projects in the future.
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9.0 REFERENCES
a) Internet
https://www.3erp.com/blog/cnc-lathe/
https://www.rapiddirect.com/blog/what-is-cnc-turning/
https://www.madearia.com/blog/cnc-turning-explained-process-operations-and-
advantages/
https://get-it-made.co.uk/resources/what-is-cnc-turning
https://www.collegesidekick.com/study-docs/1535792
https://www.3erp.com/blog/computer-numerical-control/
https://www.acu-rite.com/pdf/anilam/ANILAM_5000_Support/
5000M_Training_2.pdf
https://www.xometry.com/resources/machining/parts-of-a-cnc-machine/
b) Books
Bob Quesada. Computer Numerical Control Machining and Turning Centers
(2013), Pearson Education. (ISBN: 9780133407754, 0133407756)
Pawan Negi, Mangey Ram, Om Prakash Yadav. Basics of CNC Programming
(2022), River Publishers. (ISBN: 9781000792911, 1000792919)
Michael Lynch, Mike Lynch, CNC Turning Center Programming, Setup, and
Operation 2nd Edition A Guide to Mastering the Use of CNC Turning Centers
(2017), CreateSpace Independent Publishing Platform. (ISBN: 9781546948094,
1546948090)
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