DMM3663 CNC TECHNOLOGY
GROUP PROJECT
LECTURER : MR. NGUI WAI KENG
J.P : EN. ASMIZAM
SECTION : M01
GROUP MEMBERS :
No. Name ID
1 TAN LI XUE MB14122
2 DANIAL AIMAN BIN MOHAMAD MB14089
3 MUHAMMAD AFIQ BIN SUMONO MB14126
4 SHAHRUL AMIN BIN MOHAMAD SUKRI MB14157
5 MUHAMMAD ARIEF ASYRAF BIN KAMARUDIN MB14161
6 NOR IZZATI BINTI KAMAL BAHROM MB14148
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1.0 INTRODUCTION
Computer Numerical Control (CNC) Machining is a process used in manufacturing
sectors that involve the use of computers to control machine tools. Tools that can be controlled
in this manner includes lathes, mills, and grinders. In CNC machining process, the CNC
machine is controlled by a computer program containing CNC machining language such as
preparatory (G codes) and miscellaneous (M codes) functions that essentially controls all
features such as feed rate, spindle speed on/off, tool change, coordination, location and coolant
on/off. In this group project, a CNC milling machine is introduced to students in order to
complete the project.
1.1 OBJECTIVES
Basically, the objectives of the project are:
To design a product.
To create a coding program based on the design of the product.
To operate a CNC machine for the fabrication of the product.
1.2 SCOPES OF THE PROJECT
In general, this project was conducted to design and fabricate a product using a CNC
machine. A dimension of 100mm x 100mm x 30mm aluminium workpiece was provided to
each group in order to produce a prototype based on the drawing design by using CNC machine.
The design of the product was done using SolidWorks 2014 software. Then, coding for the
product was done in notepad and a simulator is used to check the coding before proceeding to
the fabrication of the product using CNC machine. The coding of the product involved milling,
drilling, and subprogram. In the operation of the CNC machine, tools such as end mill, center
drill, and drill bit are used. From the fabrication, we can determine whether the coding for the
product is correct or not.
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2.0 METHODOLOGY
2.1 PROJECT FLOW CHART
There is a planning of the overall progress to assure the project can be finished smoothly
on schedule. The project begins with a brainstorming process. Brainstorming with group
members is important in order to create ideas, solve problems, motivates and develop teams.
Through this process, a sketch design for the product is made based on the ideas given by group
members. After several designs of the product are sketched and considered, the most suitable
design for the product has been chosen in order to product the product. The selected design is
then submitted to the instructor from the laboratory for further revising. If the design is
infeasible, everything will go back to the brainstorming stage. If the design is feasible, the
selected design will be transferred to solid modelling and engineering drawing using
SolidWorks 2014 software.
Once the engineering drawing finished, coding of the product is made according to the
design of the product. The coding is a computer program containing CNC machining language
which is then transferred to the Machine Control Unit (MCU) of the CNC machine. The CNC
machine will then fabricate the product according to the coding. After finishing the codes of
the product, the coding is then transferred to the simulator for the detection of errors. If the
simulation is failed, everything will return to the previous stage, which is the coding of the
product. In other words, if the simulation is successful, this will proceed to the next stage,
which is the fabrication of the product, by transferring the coding into the CNC machine.
After the fabrication stage, when all materials for report writing are gathered, this
proceeds to report writing process and presentation making process. The project is ended after
the submission of the product, final report, and the slide presentation that has been presented.
Figure 2.1 shows the flow chart of this group project.
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Start
Brainstorming
Design Product
No
Product Design
Checking
Yes
Do Coding for the Product
No
Coding Checking
using Simulator
Yes
Fabrication of Product by
CNC Machine
Inspection of the Product
Report Writing and Final
Presentation
Submission of Report and
Presentation Slides
End
Figure 2.1: Project Flow Chart
4
2.2 SOLIDWORKS DRAWING OF THE PRODUCT
Figure 2.2 shows the 3D drawing of the product while figure 2.3 shows the 2D drawing
of the product.
Figure 2.2: 3D Drawing of the Product
Figure 2.3: 2D Drawing of the Product
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2.3 CALCULATION INVOLVED
There are several important parameters that need to be considered in this project, which
are feed rate, spindle speed and depth of cut. The workpiece is made of aluminium material. It
is assumed that the cutting speed for an aluminium material is 50. The calculations formulas
that involved in this project are:
𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑 × 1000
𝑅𝑃𝑀 =
𝜋×𝐷
𝐹𝐸𝐸𝐷 𝑅𝐴𝑇𝐸 = 𝑛𝑜 𝑜𝑓 𝑡𝑜𝑜𝑡ℎ × 𝑅𝑃𝑀 × 𝑐ℎ𝑖𝑝 𝑙𝑜𝑎𝑑
By using the formulas given, the relevant parameters of the design of the product are
calculated and recorded in the table below:
Table 2.1: Important Parameters of the Product Design
No Process Tool RPM Depth Total Feed Remark
(rev/min) of Cut Depth rate
(mm) (mm) (mm/
min)
1. W/P ZP Edge finder 100
(G54)
2. Total length Tool
(G43) Presetter
3. MILLING End Mill
T1 (Profile Milling) T1: 18mm 884 5 10 250 T1
T2 (Profile Milling) T2: 10mm 1591 10 10 100 T2
4. DRILLING
T3 (Center Drilling) Center Drill 1000 6 6 50 T3
T4 (Deep Hole Drill 1193 15 15 50 T4
Drilling) T4: 8mm
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2.4 CODING OF THE DESIGN
2.4.1 MAIN PROGRAM (O1234)
%
O01234 (UMP);
N5 G17 G40 G49 G80 G90 G21;
N10 M06 T01;
N15 G54 G00 X-60. Y0. Z10. ;
N20 M03 S884;
N25 G43 H01 Z1. M08;
N30 G01 Z-10. F50. ;
N35 G41 X-50. Y0. D01 F250. ;
N40 Y50. ;
PROFILE MILLING (SQUARE-OUTSIDE)
N45 X50. ;
N50 Y-50. ;
N55 X-50. ;
N60 Y0. ;
N65 G02 X0. Y50. R50. ;
N70 X50. Y0. R50. ;
N75 X0. Y-50. R50. ;
N80 X-50. Y9. R50. ;
N85 G01 X-60. ;
PROFILE MILLING (CIRCULAR)
N90 G02 X0. Y60. R60. ;
N95 X60. Y0. R60. ;
N100 X0. Y-60. R60. ;
N105 X-60. Y0. R60. ;
N110 G00 Z5. ;
N115 G40;
N120 G54 G00 X-35. Y35. ;
N125 G83 G99 Z-10. R1. Q2. F50. ;
DEEP HOLE DRILLING
N130 M98 P1110;
N160 G49 G28 M09;
N165 M05;
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N170 M06 T02;
N175 G54 G00 X-60. Y0. ;
N180 M03 S1591;
N185 G43 H02 Z1. M08;
N190 G01 Z-10. F100. ;
N195 X-60. Y0. ;
N200 X-25. ;
N205 G00 Z5. ;
N210 X0. Y60. ;
N215 G01 Z-10. ; SLOT MILLING
N220 Y25. ;
N225 G00 Z5. ;
N230 X60. Y0. ;
N235 G01 Z-10. ;
N240 X25. ;
N245 G00 Z5. ;
N250 X0. Y-60. ;
N255 G01 Z-10. ;
N260 Y-25. ;
N265 G00 Z5. ;
N270 X-25. Y0. ;
N275 G01 Z-5. F50. ;
N280 G42 D02 X-25. ;
N285 G01 Y17. ;
N290 G02 X-17. Y25. R8. ;
N295 G01 X17. Y25. ;
N300 G02 X25. Y17. R8. ; PROFILE MILLING (SQUARE-INSIDE)
N305 G01 Y-17. ;
N310 G02 X17. Y-25. R8. ;
N315 G01 X-17. ;
N320 G02 X-25. Y-17. R8. ;
N325 G01 Y5. ;
N330 G00 Z5. ;
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N335 X-12. Y70. ;
N340 G01 Z-5. F50. ;
N345 Y0. ;
N350 X0. Y-15. ;
N355 X12. Y0. ;
N360 Y15. ;
N365 Z-2. ;
PROFILE MILLING (UMP LOGO)
N370 X-4. ;
N375 Y0. ;
N380 X0. Y-5. ;
N385 X4. Y0. ;
N390 Y20. ;
N395 G00 Z5. M09;
N400 G40 G49 G28 M05;
N405 M06 T03;
N410 G54 G00 X-35. Y15;
N415 M03 S1000;
N420 G43 H03 Z1. M08;
CENTER DRILLING
N425 G81 G99 Z-6. R1. F50. ;
N430 M98 P1112;
N480 G49 G28 M05;
N485 M06 T04;
N490 G54 G00 X-35. Y15. ;
N495 M03 S1989;
DEEP HOLE DRILLING
N500 G43 H04 Z1. M08;
N505 G83 G99 Z-15. R1. Q2. F50. ;
N510 M98 P1112;
N515 G49 G28 M05;
N520 M30;
%
9
2.4.2 SUBPROGRAM (O1110)
%
O01110;
N135 X35. Y35. ;
N140 X35. Y-35. ;
N145 X-35. Y-35. ;
N150 G80 G00 Z1. M09;
N155 M99;
%
2.4.3 SUBPROGRAM (O1112)
%
O01112;
N435 X-15. Y35. ;
N440 X15. Y35. ;
N445 X35. Y15. ;
N450 X35. Y-15. ;
N455 X15. Y-35. ;
N460 X-15. Y-35. ;
N465 X-35. Y-15. ;
N470 G80 G00 Z1. M09;
N475 M99;
%
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2.5 PROCESS FLOW
(A) Initial Preparation for CNC Machining
1. Before any process begins, the CNC machine is cleaned from all the material scraps
and chips by using the blower.
2. The cleaning process is important to ensure that CNC machining process will be going
smoothly without any problem.
3. The clamp is prepared and fit perfectly into the slot.
4. Parallel bars are placed under the workpiece to make sure that the workpiece had been
clamped by 10mm.
(B) Setting Tool Sequence
1. After cleaning the machine, the tools that need to be used are set according to the
following sequence:
The first tool is an end mill, with the diameter size of 18mm and the coding for the tool,
is M06 T01.
The second tool is also the end mill, with the diameter size of 10mm and the coding for
the tool, is M06 T02.
The third tool is a center drill and the coding for the tool, is M06 T03.
The fourth tool a drill, with the diameter size of 8mm and the coding for the tool, is
M06 T04.
The fifth tool is an edge finder and the coding for the tool, is M06 T05.
(C) Setting the centre point of the workpiece
1. In this project, the origin has been set at the centre point of the workpiece.
2. So, edge finder is used in order to find the origin of the workpiece.
3. Firstly, the edge finder is moved in x-axis direction to find the actual dimension of the
workpiece in the x-axis.
4. Coordinate is set to be zero once the edge finder stopped shaking when it touches the
surface of the workpiece. The measurement in the x-axis direction is recorded.
5. Step 3 to 4 are repeated in order to get the actual dimension of the workpiece in the y-
axis direction. After getting the measurement in both x-axis and y-axis, the
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measurements are divided into two so that the centre point/origin of the workpiece can
be obtained.
(D) Setting Height Compensation
1. In this case, tool presetter is used and placed on the top surface of the workpiece.
2. Firstly, the first tool is lowered in order to touch the surface of the tool presetter until
the scale on the tool presetter to reach zero.
3. After that, a value of Z-50 is set to the offset table in the MCU of the CNC machine.
4. Steps 1 to 3 is repeated for another three tools.
(E) Facing
1. The surface of the workpiece is milled -0.3mm with the purpose of removing the
corrosion surface of the workpiece.
(F) Milling
1. Firstly, the four sides of the workpiece are milled in order to obtain an exact dimension
of 100mm x 100mm. In this process, the first tool (End Mill) with the diameter size of
18mm is used.
2. The origin of the workpiece is set to be at the centre of the workpiece. G00 is used to
command the tool to move to the parking position (-60, 0). Then, G01 is activated to
lower the tool by -10mm and move the tool to (-50, 0). G41 is then activated to start
milling the four sides of the workpiece in a clockwise direction. The process is ended
when the tool returns to its initial coordinate (-50, 0). Figure 2.4 shows the profile
milling on the four sides of the workpiece.
Figure 2.4: Profile Milling (Square-Outside)
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3. At the same coordinate, G02 is activated to move the tool in a clockwise direction with
a radius of 50mm, getting a circular shape on the top surface of the workpiece. The
process is ended when the tool return to its initial coordinate (-50, 0) again. Figure 2.5
shows the circular profile milling on the top surface of the workpiece.
Figure 2.5: Profile Milling (Circular)
4. After the circular profile milling process, the same tool is used to drill four holes on the
workpiece with a depth of cut of 10mm. G40 is activated to cancel the left cutter
compensation while G00 is activated to raise the tool by 5mm above the workpiece and
move it to the coordinate (-35, 35) for the first hole drilling.
5. Then, G83 is activated to drill the first hole on the workpiece. A subprogram O1110 is
then called by M98 to drill another three holes on the workpiece. The process is ended
by activating G00 code to raise the tool to a safe position. Figure 2.6 shows four holes
that are drilled on the workpiece.
Figure 2.6: Deep Hole Drilling
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6. The next process is slot milling. In this process, the second tool with the diameter size
of 10mm is used in order to replace the first tool.
7. Four slots are made on the workpiece with the depth of cut of 10mm. Since the depth
of cut is large, so the feed rate in this process is set to be 100mm/min. After the last slot
is milled, the tool is raised by 5mm above the workpiece. Figure 2.7 shows the four
slots that are milled on the workpiece.
Figure 2.7: Slot Milling
8. Using the same tool, G42 is activated to perform a square profile milling at the centre
of the workpiece. A UMP logo on the workpiece is also milled using the same tool.
9. After milling, the tool is raised to 5mm above the workpiece for safety purpose. Figure
2.8 shows the steps on how a UMP logo are milled on the centre of the workpiece.
Figure 2.8: Profile Milling (UMP Logo)
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(G) Center Drilling and Deep Hole Drilling
1. In the center drilling process, the third tool which is center drill is used.
2. G00 code is activated to move the tool to the coordinate (-35, 15) of the first hole to be
drilled. G81 is then activated to drill the hole with the depth of -6mm is. By activating
M98, a subprogram (O1112) is called to drill another seven holes. The process is ended
by raising tool 5mm above the workpiece.
3. The next process is deep hole drilling process. In this process, the fourth tool with the
diameter size of 8mm is used to replace the third tool.
4. Once again, G00 is activated to move the tool to the coordinate (-35, 15) of the first
hole to be drilled. For deep hole drilling, G83 is activated to drill the hole with the depth
of -15mm. By activating M98, the subprogram (O1112) is called again in order to drill
another seven holes. The process is ended by raising the tool 5mm above the workpiece.
Figure 2.9 shows the holes that are drilled on the workpiece.
Figure 2.9: Center Drilling and Deep Hole Drilling
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3.0 RESULTS AND DISCUSSION
3.1 RESULTS
Figure 3.1 shows the prototype that was produced based on the drawing using CNC
machine. From the figure 3.1, it can be seen that the prototype was successfully developed
according to the coding that was made.
Figure 3.1: Fabricated Product
3.2 DISCUSSION
During the completion of this group project, there are several problems faced by every
group member. The first problem faced was the design of the product. Initially, the first
iteration design was the Android logo design on the aluminium workpiece provided. However,
the design was rejected by the instructor in laboratory due to the complexity of the design and
the difficulty to fabricate it. Then, in order to counteract this problem, second iteration design
was developed, which is the design that had been used in this project. The finalized design
involved the process such as milling, drilling, and subprogram.
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Besides, one of the problems faced by group members was the coding process. Once
the coding of the product completed, the coding file was then transferred to the simulator for
the detection of errors. During this process, there are some errors appeared on the screen of the
simulator. With the guidance and help of instructor and M01 coursemates, all the errors can be
solved easily.
Not only that, during setting the height compensation, tool presetter was been used. In
this process, each tool has to be lowered to come near to the surface of tool presetter until the
scale on the tool presetter reaches zero. However, a center drill tool was broken when setting
the height compensation. This is due to one of the group members turned on the power of the
hand jog into high power which caused the tool to lower faster and hit the tool presetter. The
solution attempted was by replacing the broken center drill to a new one. Through this process,
a lesson is learned to handle the hand jog carefully especially for the beginner during the
operation of the CNC machine.
Furthermore, there was another case of end mill tool broken happened during the slot
milling process. In this process, four slots with a depth of -10mm is milled on the workpiece at
the feed rate of 250mm/min. However, the tool was broken when it started to mill the workpiece
due to the wrong adjustment of the feed rate. So, in order to solve the problem, the feed rate
was then adjusted to 100mm/min.
Lastly, during the deep hole drilling process, a drill bit was broken. This happened
because a -50mm in z-axis had set when the tool on the top surface of the workpiece. Initially,
one of our group members had set the z-axis with the correct coordinate, but with the added -
50mm to the coordinate, this caused the tool rapid tooling and hit the surface of workpiece
hardly. So, a broken drill bit that stocked in the first drilled hole on the workpiece can be seen
in figure 3.1.
During the operation of the CNC machine, there are several precautions and safety rules
that have been taken seriously throughout the project. First of all, it is necessary to make sure
that the workpiece is properly clamped and secured in the machine. Before the tool starts to
mill the workpiece, ensure that the coolant is turned on and the machine door should be closed
to prevent any injury. After the operation of the machine, the machine is cleaned by removing
all the debris of the workpiece.
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3.3 PRECAUTIONS
CNC machine is a machine that doing machining process based on the user
programming or codes. The user just input all the coding and the machine will read it and
intepret it by doing machining. The machine was automatic and will cause less hazard
compare than machining by manually. However, there is still precaution when handling
CNC.
Firstly, make sure that the surface at placement of workpiece is clean and free from
the metal scrap. Use the air gun to clean the surface. This to ensure the workpiece will not
effected by the metal scrap as will cause some scratch at the workpiece. This also to ensure
the machining process will be done smoothly without any disturbance.
Next precaution is, make sure that the workpiece have been clamped in a correct way.
Use the parallel bars when clamping the workpiece as it will support and be a stand for the
workpiece to be clamped upper part of the clamp. This to ensure the machining will only
occur at the surface of workpiece and not to the clamp.
After that, when inserting the tools, the user need to be extra careful when handling
the tools as it was very sharp. Take a cloth and hold the tools when insert it. Misshandling
will cause a serious injury.
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4.0 CONCLUSION
In conclusion, a prototype was successfully developed using a CNC machine. The result
of the prototype had indicated that the coding of the product was correct. Despite there are
several problems that we faced in this project, however, all the problems can be solved easily
and the prototype was successfully developed according to the coding. Throughout the project,
it is important to take serious attention on the operation of the CNC machine in order to prevent
any injury. The project also had achieved all the project objectives which had been stated
previously.
5.0 REFERENCE
http://www.productivity.com/wp-content/uploads/2015/04/Haas-Mill-Operator-
Manual.pdf
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