ABSTRACT
The aim of the project is to manufacture the designed profile by using CNC machine.
The profile designed is needed to write a CNC program based on labels, the label mode of
program is selected because the programming is too easy even for complicated shapes.
CNCs had made revolutionary changes with in the manufacturing sector in before days
achieving productivity up to the desired level was not possibilities due to lots of drawbacks
like complication of shapes and sizes, lack of skilled labors ,lots of wastages and scraps due
to unexpected mistakes and low quality levels and accuracy. By using CNC this all draw
backs can be overcome and this was our small contribution to show the performance of CNC.
Initially we got trained about the CNC programming and operations for the period of
one month during the training decided to carry our project on CNC , we designed a profile
to be manufactured which would be tough to achieve it by conventional machining process
and we designed to make use of aluminum material as a work piece of dimension, after the
basic selections and decisions the preparation of an program (based on labels) was done and
we went for simulation and verified it thoroughly weather the profile achieved by simulation
is matching to the designed after lots of observation we went for manufacturing the profile in
CNC machine available at the source place and the results we got was smooth finished
surface with high rate of accuracy with less machining time which directly increases the
productivity and the process would be economical when compared to the normal
conventional machining process.
CONTENTS
CHAPTER NO TITLE PAGE NO
ABSTACT
CHAPTER 1
INTRODUCTION 1-11
1.1 Machine 1
1.2 Conventional Machines 1
1.3 Numerical Control Machine 4
1.4 Introduction of CNC Machine 6
1.5 Working of CNC Machine 7
1.6 Various Types Of CNC Machines 8
1.7 Advantages 8
1.8 Limitations 9
1.9 Applications of CNC Machine 9
CHAPTER 2
CNC PROGRAMMING BASICS 12-23
2.1 Coordinating System 12
2.2 Programming System 15
2.3 Incremental and Absolute systems 17
2.4 Part Programming in CNC 19
2.5 Preparatory Codes 20
2.6 List of G-Codes & M-Codes 21
CHAPTER 3
CNC SOFTWARES 24-35
3.1 CNC Softwares Introduction 24
3.2 SINUMERIK 828D 26
3.3 Versions of the SINUMERIK 828D 28
3.4 Tool Management 31
3.5 CNC Stimulation 32
3.6 Optimum View Guaranteed 33
CHAPTER 4
HISTORY AND DEVELOPMENT OF CNC MACHINE 36-44
4.1 History of N.C Machine 36
4.2 Changes from NC to CNC System 37
4.3 Common CNC Machine 39
4.4 Development Between Conventional and Non convectional machine 42
4.5 Difference Between Conventional and Non convectional machine 44
CHAPTER 5:
ACTUAL PROJECT PROGRAM 45-53
5.1 Aim 45
5.2 Description 45
5.3 Designing of Profile 45
5.4 Profile Programming 46
5.5 Manufacturing of The Profile By Using CNC Smartrun Lathe Machine 53
CHAPTER 6:
RESULT & CONCLUSIONS 57-59
6.1 Results 57
6.2 Conclusion 58
REFERENCES 59
PHOTO GRAPHS 60-61
FIGURES
FIGURE NO TITLE PAGE NO
Fig. 1.1 Conventional Lathe Machine 3
Fig. 1.2 Conventional Grinding Machine 4
Fig. 1.3 NC Milling Machine 6
Fig. 1.4 NC Lathe Machine 6
Fig. 1.5 CNC Lathe Machine 10
Fig. 1.6 CNC Milling Machine 11
Fig. 2.1 Intersecting Lines from Right Angles 13
Fig. 2.2 The Three Dimensional Coordinate System 13
Fig. 2.3 Three Finger Rule 13
Fig. 2.4 Three Hand Rule 14
Fig. 2.5 Quadrant system 15
Fig. 2.6 Programming System 16
Fig. 2.7 A Work Piece Dimensioned in the Absolute System Mode 17
Fig. 2.8 Difference between Absolute And Incremental Positioning 18
Fig. 3.1 SINUMERIK 828D 25
Fig. 3.2 Keyboard 25
Fig. 3.3 SINUMERIK 828D 27
Fig. 3.4 Milling Machining Setting up and Getting Started 29
Fig. 3.5 Turning Machining Guaranteed to Turnout Well 30
Fig. 3.6 Tool Management 31
Fig. 3.7 CNC Stimulation 32
Fig. 3.8 Optimum View 33
Fig. 3.9 SINUMERIK 828D Alignment 34
Fig. 4.1 Numerical Control Machining Began in Aircraft Industry 35
Fig. 4.2 NC Machine 36
Fig. 4.3 New CNC Machines 36
Fig. 4.4 Tape Reader 37
Fig. 4.5 CNC Machine Key 37
Fig. 4.6 CNC Machines May Contain Many Tools 37
Fig. 4.7 CNC Milling Machine 38
Fig. 4.8 CNC Lathe Machine 39
Fig. 4.9 CNC Grinding 39
Fig.4.10 CNC Punch Press Use One Tool 39
Fig. 5.1 Profile Design 45
Fig. 5.2 Profile Program 49
Fig. 5.3 Work Piece Dimensions 50
Fig. 5.4 Stock Removal 51
Fig. 5.5 Grooving 51
Fig. 5.6 2-D Simulation 52
Fig. 5.7 3-D Simulation 52
Fig. 5.8 Half cut Simulation 53
Fig. 5.9 Aluminum Work Piece 54
Fig. 5.10 Tools Used 55
Fig. 5.11 Profile Manufacturing 55
Fig. 5.12 Machining Process 56
Fig. 6.1 The profile Output 57
