Lab Manu.docx

FACULTY OF MECHANICAL ENGINEERING UNIVERSITI TEKNOLOGI MARA (UITM)

LABORATORY REPORT

PROGRAM COURSE COURSE CODE LABORATORY NAME LECTURER NAME TITLE OF EXPERIMENT GROUP

NO. 1 2 3 4 5

: : : : : : :

Bachelor of Engineering (Hons) Mechanical (EM220) Manufacturing Processes Laboratory MEM564 Machining Radzuan A. Rahman CNC Milling (Non Traditional Machining) EMD5M9A/10

STUDENT NAME NOR NABILAH BINTI CHE ABD RAHIM NUR AFIQAH BT KAMARUDZMAN NUR DHANIA BT NADZRI NUR SHAZWANI BT ALIDZA NUR ZAKIAH BINTI MOHD RAFEE

STUDENT ID NUMBER 2015829412 2015217382 2015208522 2015839554 2015208746

SIGNATURE

DATE OF PRACTICAL SESSION

STAFF CERTIFICATION (SIGNATURE)

DATE OF REPORT SUBMISSION

STAFF CERTIFICATION (SIGNATURE)

2

TABLE OF CONTENTS

TABLE OF CONTENTS......................................................................................................1 1.0

TITLE....................................................................................................................2

2.0

OBJECTIVES..........................................................................................................2

3.0

INTRODUCTION...................................................................................................2

4.0

APPARATUS..........................................................................................................4

5.0

EXPERIMENTAL PROCEDURE...............................................................................4

6.0

RESULTS & DATA ANALYSIS..................................................................................4

7.0

DISCUSSION OF RESULTS.....................................................................................5

8.0

CONCLUSION.......................................................................................................9

9.0

RECOMMENDATION............................................................................................9

10.0 REFERENCES......................................................................................................10

1

1.0

TITLE CNC Milling (Non-Traditional Machining)

2.0

OBJECTIVES i. ii.

3.0

To design a basic NC program for CNC Milling To machine a product using the CNC milling

INTRODUCTION A non-traditional manufacturing process is defined as a group of process that remove accessed material by various techniques based on different source of energy. The cutting source may in the form of mechanical, thermal, electric or chemical energy or combinations of these energies without any direct contact of sharp cutting as in traditional machining. Extremely hard and brittle materials are difficult to machine by traditional machining process such as turning, drilling, shaping and milling. Non-traditional machining processes are graphed in advanced manufacturing processes. It is employed when traditional machining processes are not feasible and due to certain satisfactory justification to special reasons. Numerical control is a method of controlling the movement of the machine. This program controlling the movement of the component on the machine by directly inserting the code of instructions into the system. The system interprets data and convert them to output signal. In numerical control operations, data concerning all aspects of the machining operation, such as tool location, speeds, feeds, and cutting fluids are stored on hard disk.

2

Figure 3- 1 CNC Milling Machine

The instructions code can be performed by computer software such as CATIA that produce numerical code from geometry data files. The program contains the following instructions and command: i.

Geometric instructions pertain to relative movements between the

ii.

tools and the workpiece. Processing instructions concern spindle speeds, feeds, cutting tools,

iii.

cutting fluids and so on. Travel instructions pertain to the type of interpolation and to the

iv.

speed of movement of the tool or the worktable. Switching instructions concern the on-off position for coolant supplies, direction or lack of spindle rotation, tool changes, workpiece feeding, clamping and so on.

Computer-aided Manufacturing (CAM) involves the use of computers to assist in all phases of manufacturing a product. The combination of Computer-aided Design (CAD) and CAM allows the transfer of information from the design stage to the planning for manufacturing stage. There is no necessity to enter the data on part geometry manually. The database developed during CAD is stored and further processed by CAM into the relevant data and instructions for the operating and controlling production machinery, material-handling equipment and automated testing and inspection for product quality.

3

4.0

APPARATUS i. ii. iii. iv. v. vi.

5.0

EXPERIMENTAL PROCEDURE 1. 2. 3. 4.

6.0

NC Program Machine controller Rough stock CNC milling machine Work holding devices Cutting tool

The NC programming was designed using CATIA software. The NC program was uploaded in Computer Aided Manufacturing (CAM). The workpiece was prepared and the machine was setup. Milling process was started.

RESULTS & DATA ANALYSIS Developed NC Program using CATIA software

End product of machined rough stock

4

7.0

DISCUSSION OF RESULTS Computer Aided Machining or Manufacturing (CAM) refers to the use of various software packages to create toolpaths and NC code to run a CNC controlled machine, based on 3D computer model (CAD) data. When the two are used together, this is generally referred to as CAD/CAM. CAM does not actually run the CNC machine, but just creates code for it to follow. It is also not an automatic operation that imports your CAD model and spits out the correct NC code. Most NC today is computer numerical control (CNC), in which computers play an integral part of the control. In modern CNC systems, end-to-end component design is highly automated using computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The CNC machine is programmed by using CAM software which uses the software to apply tool paths to a 3D or 2D model of the part desired. FANUC is developed as an early numerical control (NC) and servo systems, it is an acronym for factory automation numerical control. A special relatively simple computer language that a CNC machine can understand and execute is NC code. These languages were originally developed to program parts directly at 5

the machine keyboard without the aid of a CAM program. They tell the machine what moves to execute, one by one, as well as controlling other machine functions such as spindle and feed speeds, coolant. The most common language used in this workshop session is G-code and M-code. From the result, the NC program starts with a ‘%’ symbol which indicates FANUC language, and the first to 6th commands (N1-N6) are inputs of the tool bit detail and positioning of the axis of origin which includes: G4 9 G6 4 G1 7 G8 0 G0 G9 0

Tool length compensation cancel Cutting mode

G40 Cutter compensation cancel

Circular interpolation plane selection XY Canned cycle cancel

M6

Start tool change

M3

Spindle on clockwise

Rapid positioning Absolute positioning mode

G43 Tool length compensation (+) G1 Linear interpolation

G99 R point return

In the end of the machining, the CNC program instructed the machine to switch off the spindle (M5) and restart the program (M2). In this workshop, poly (methyl methacrylate) (PMMA), also known as acrylic or acrylic glass as well as by the trade names Plexiglas, Acrylite, Lucite, and Perspex is used. It is a transparent thermoplastic often used in sheet form as a lightweight or shatter-resistant alternative to glass. The material that had been removed is called "chips" and it will usually be recycled.

6

Figure 7- 2 Type of material used; Perspex.

Once the programming is done, it is fed into a post processor which will turn the CAM program into the M and G code the machine can read. The codes are then uploaded into the CNC machine along with all the cutting tools needed, raw material and work holding needed to hold the raw material. Then the machine is put into automatic mode and start the program to make the part.

Figure 7- 3 The codes are uploaded into the CNC machine & being read to perform the process automatically

7

Figure 7- 4 The workpiece while being carved into desired shape

Lubricant is used as all moving parts in a machine require lubrication, that is, the application of oil to reduce friction between them. As it reduces friction, the Perspex used wont melt from heat produced between the tools.

Figure 7- 5 Lubricant is applied to reduce friction between the workpiece and the tool bit

The quality of the end product of the machining process is not that satisfying as it doesn’t resembles the CAD file of the product. This might be due to the errors during the process setup. To get a better finish, the fine cut should be decreased. 8

8.0

CONCLUSION In the industrial world, time is money. Where all business owners would like to have an abundance of both. Utilizing the CNC machine monitoring and reporting systems, it will maximize the production efficiency, train production personnel to be aware of their inactivity, and provide our production management team with the tools to improve the output. In conclusion, the objective of this experiment has been successfully achieved as a product had been made by using a basic NC program design on the CNC Milling machine. The using of the NC program in CNC Milling help a lot in reducing the time and make it simple in handling the milling process. The machine can be used to produce complex shapes and precise product with high dimensional accuracy. Besides, it can reduce the scrap loss. Milling machines are being replaced rapidly by this CNC Machines which are more versatile and capable of milling, drilling, boring and tapping with repetitive accuracy.

9.0

RECOMMENDATION Catia, computer aided design (CAD) is a software used to draw or design the shape of the product to be machined. The data or design have to be transferred manually from the computer to the machine via thumb drive. Some of the time, the data transferred cannot be read by the machine, due to some errors during the transfer process. As a recommendation, we can attached the design software to the machine, so that we don't have to transfer the data to the machine manually. This will minimize the error and will reduced time taken to transfer the data using transfer tools. During the process, the workpiece will be machine for a long period of time and it can make the cutting tool blunt. Besides, it can also produce heat, which can melt or break the workpiece also, producing a rough surface finish. To prevent that from occurring, lubricant or oil can be introduced during the 9

cutting process. Currently, applying the lubricant is done manually by hand. This is a hassle as an operator need to be there during the machining process to keep an eye on the workpiece as the machining process runs. As a recommendation, we can install an automated lubricant system which can cool the tool bit and the workpiece efficiently. Some of the workpiece or product is extremely complex so there was plenty of chips after the machining process. The chips was scattered all over the machine. As recommendation, we can put additional component such as a box or tray under the machine so that it will make it easier to clean up the chips.

10.0

REFERENCES 1. Serope Kalpakjian, Manufacturing Engineering and Technology, 6th Edition, Illinois Institute of Technology, Prentice Hall, 2010. 2. John A. Schey, J.A., "Introduction to Manufacturing Processes", 5th Edition, McGraw-Hill, 2000. 3. Mikell P Groover, Principles of Modern Manufacturing, SI Version, 4th Edition, John Wiley & Son, Inc., 2011. 4. P N Rao, Manufacturing Technology, Metal Cutting and Machine Tools, Universiti Teknologi Mara, Malaysia, Tata Mc Graw Hill, 2000.

10