Microproject on cnc milling machine
- 1. CNC MILLING Whats is Horizontal CNC milling machine Horizontal CNC milling refers to CNC milling operations that utilize horizontal milling machines. As suggested by the name, the machines have horizontally oriented tooling — with rotating cylindrical cutters that can move along up to five axes to create the shapes, slots, details, and holes of a three-dimensional part. This design makes them suitable for both end milling and plain milling; the former uses tools with teeth on the periphery and face, while the latter uses tools with teeth only on the periphery.
- 2. A horizontal milling machine is consists of the following basic components. 1) Base: the main part of various types of milling machine, along with column, used to support the table and align, hold the machine. 2) Table: used to hold and secure the work piece to be machined. 3) Column: along with the base, to hold, align and support the machine. 4) Knee: can move up and down to position the piece, supports the saddle and table. 5) Saddle: attached to the knee, provides in and out, or Y-axis table travel. 6) Spindle: mounted with the cutting tool, holds the tool and provides rotation. 7) Overhanging arm: align and support the arbor support. 8) Arbor support (bracket): attached to the overhanging arm, supports the end of arbor that is opposite the spindle. 9) Arbor What are the Main Parts of a Horizontal Milling Machine? - Construction of Horizontal Milling Machine
- 4. ELEMENTS OF ACNC A CNC system consists of three basiccomponents: ➢ Part program ➢ Machine Control Unit (MCU) ➢ Machine tool (lathe, drill press, milling machine etc.)
- 5. CNC Horizontal Machining: Tools and Variations ▪CNC Horizontal Lathes Especially effective for complicated programs that would overwhelm a manual lathe, CNC horizontal lathes make fast, precise cuts while a workpiece is being rotated on a horizontal axis. ▪CNC Horizontal Machining Centers This modern style of milling machine comes supported with a full system of additional features, such as automatic tool changers, carousels and magazines, coolant and cutting fluid systems, and specialty enclosures. ▪CNC Horizontal Boring Machines or Boring Mills There are three main varieties of this tool: table, planer, and floor. The table is the most universal, though all serve the same purpose of boring holes into a workpiece horizontally
- 6. Types of Milling The CNC milling process can be broken up into four distinct stages: CAD model design: engineers create a 2D or 3D design of the desired part CAD model conversion to a CNC program: the design is exported into a compatible file format and converted into machine instructions using CAM software CNC milling machine setup: the machine operator prepares the machine and workpiece Milling operation execution: the machine operator initiates the machining program
- 7. PART PROGRAMMING FOR CNC A typical line for a program is given below. N001 G91 X -5.0 Y7.0 F100 S200 T01 M03 The significance of each term is explained below. ▪ N-Sequence Number ▪ G-Preparatory Function ▪ Dimension Words ▪ F-Feed Rate ▪ S-Spindle Speed ▪ T-Tool ▪ M-Miscellaneous Function
- 8. G-codes • G00-Rapid positioning • G01-Linear interpolation • G02 – Circular Interpolation clock wise • G03 – Circular Interpolation counter clock wise • G16 – Polar Coordinates command • G17 – XY plane selection • G20 – Inch input • G21 – Metric input • G54 – Work piece coordinate system 1 selection • G55 – Work piece coordinate system 2 selection • G73 – Peck drilling cycle • G76 – Fine boring cycle • G80 – Canned cycle cancel • G81 – Drilling cycle • G82 – Counter boring cycle • G84 – tapping cycle • G85 – Boring cycle • G87 – Back boring cycle • G90 – Absolute command • G91 – Incremental command • G94 – Feed per minute
- 9. M-Codes • M00 – Program Stop • M01 – Optional stop • M02 – End of program • M03 – Clockwise spindle • M04 – Counter clockwise spindle • M05 – Spindle stop • M06 – Tool change • M08 – Coolant on • M09 – Coolant off • M30 – End of program & rewind
- 10. Drilling Program N001 G00 G17 G21 G90 G94; N002 G00 G54 X00 Y00 Z50; N003 M03 S600 M08; N004 G81 R5 X27 Y27 Z-10 F100; N005 X97 Y27; N006 X97 Y97; N007 X27 Y97; N008 G00 G80 Z50; N009 M05 M09; N010 M30;
- 11. PARTS SUITABLE ON CNC MACHINES ▪The following parts are usually made in practice on the CNC Machines: ▪ Aerospace equipment’s. ▪ Automobile Parts. ▪ Complex shapes. ▪ Electronic industry uses CNC e.g. Printed circuit board. ▪ Electrical industry uses CNC e.g. Coil winding. ▪ For small to medium batch quantity. ▪ Where the set-ups are very large. ▪ Where the tool storage is a problem. ▪ Where much metal needs to be removed. ▪ When the part geometry is so complex. ▪ The operations are very complex. ▪ For parts subjected to regularly design changes. ▪ When the inspection is required 100%. ▪ When lead time does not permit the conventional tooling manufacture. ▪ When the machining time is very less as compared to down. ▪ Where tool storage is a problem.
- 12. Advantages:- • Continuous Use: Unlike manual labor, CNC machinery (barring any malfunction or maintenance issue) can work continuously over any period of time without a break. This greatly increases productivity and efficiency. • Consistency, Precision and Redundancy: With computer software, the design of any given product only needs to be programmed once. The CNC machine can then perfectly replicate that design, for any order quantity. • Low Skill Requirement: CNC machine operators require little training and skill when compared to manual machine operators . • Fewer Personnel: Because computer software controls the machinery, fewer technicians are needed for operation and oversight, cutting overall expenses. • Flexibility: The software can be reprogrammed quickly and easily to produce different parts, allowing operations to keep up with shifting customer demands. • Capability: This technology uses computer precision to go beyond the limitations of manual capabilities. More complex and intricate operations are possible with CNC machining.
- 13. Disadvantages:- • Cost: CNC machines are more expensive and require a greater initial investment than machines that can be operated manually. However, as this technology becomes the standard, supply is increasing resulting in costs gradually decreasing. • Skills Loss: As the demand for manual machine operators decreases, fewer and fewer new students adopt those skills. This could eventually lead to the complete loss of long-preserved skills. • Unemployment: Automation decreases the need for manpower, and fewer laborers are hired. That said, the need is now shifting to software engineers and mechanical engineers, and education and training will have to adjust to meet that need.
- 14. parameters Doosan lynx 2100 Simens dx200 Chuck size 6” to 8” 5” to 6” Bar capacity 51mm 44mm X axis rapid travel 180mm 200mm Z axis rapid travel 174mm 500mm Tool magazine capacity 10 8 Machine weight 3175kg 3800kg Machine dimension 2319x1600x1692 mm 2500x1300x1500 mm power 15kw 20kw Spindal rpm 6000 RPM 4000 RPM Motor HP 5 HP 4.5 HP
- 15. Doosan lynx 2100 Simens DX 200