Exp 04

Khulna University of Engineering & Technology
KUET
Sessional Report
Course no: ME 4208

Department of Mechanical Engineering
Experiment no: 04
Name of the experiment: Study on CNC Lathe Machine.
Remarks:
Date of performance: 28-10-24 Name: Suvojit Baidya

Date of submission : 07-11-24 Roll:1905041
Group: A (2-3)
Year: 4th
Term: 2nd
Experiment: (4) Study of CNC lathe machine. Course no: ME 4208 (Tool Engineering & Machine Tools)
1.0 INTRODUCTION:
A Computer Numerical Control (CNC) machine is a sophisticated, automated tool that uses
programmed instructions to perform precise machining tasks. These machines are central to
modern manufacturing, used to produce complex components with high accuracy in
industries ranging from aerospace to automotive [1]. CNC machines are distinct from
traditional machining methods because they use computer-aided control to guide cutting
tools, spindles, and motors, translating complex programs written in specialized codes (such
as G-code and M-code) into precise mechanical movements [2].
CNC technology has several advantages over manual machining, primarily the ability to
reduce human error and ensure repeatability. CNC machines produce consistent results
because the process is automated, making them ideal for mass production and high-precision
applications [2]. They are available in a variety of configurations, including CNC milling,
turning, laser cutting, and waterjet machines, each optimized for a different material and
cutting technique. For example, CNC milling machines rotate cutting tools to shape
materials, whereas CNC lathes are designed to cut rotating workpieces for cylindrical
parts[3].
CNC machines' structural integrity and durability are critical to their performance because
the high-speed operations they perform cause significant stress and vibration [1]. Cast iron,
stainless steel, and even composite materials are frequently used for machine beds and other
components to provide stability and reduce deformation, which improves the machine's
longevity and precision [3].
Report on ME-4208 by Suvojit Baidya (1905041), Department of Mechanical Engineering, KUET

1
Fig 1.0: CNC lathe machine [4]
A CNC (Computer Numerical Control) lathe machine has a long history of combining
cutting-edge computer-controlled technology with traditional lathe operation to achieve
remarkable improvements in manufacturing and machining.
During World War II, engineers at MIT created the first numerical control (NC) systems to
produce complex aircraft parts, with funding from the United States Air Force. Engineer
John T. Parsons used punch cards and coded instructions to control machines, which
significantly increased precision and reduced manual errors. [5].
The transition from NC to CNC occurred with the advent of computers in the 1960s and
1970s. CNC (Computer Numerical Control) integrated computers to improve speed,
precision, and flexibility over NC systems. The first commercial CNC machines were
introduced in the late 1970s, marking a substantial shift toward automated, computer-
controlled manufacturing. These machines, including lathes, could be reprogrammed for
different tasks, further revolutionizing production.[4]
From the 1980s onwards, CNC lathe machines became essential in manufacturing, especially
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in the automotive, aerospace, and electronics industries. They enabled multi-axis machining,
automatic tool changing, and greater customization. Advanced software, higher precision,
and increased productivity turned CNC lathes into a staple for high-volume, consistent
quality production. Today's CNC lathes use high-speed internet, IoT, and AI integration,
making manufacturing smarter and more efficient.
The basic CNC process can be divided into three steps. The engineer first creates a CAD
model of the part. The machinist then converts the CAD file into a CNC program (G-code)
and configures the machine. Finally, the CNC system carries out all machining operations
with little supervision, removing material and creating the part [5]
2.0 Objectives:
The main objective of the study of CNC lathe machines are,

i. To study CNC lathe machine.
ii. To develop program for fabricating a mold.
iii. To model a mold by using Solidworks.
iv. To fabricate a mold using the developed program.

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3.0 Principle of CNC lathe machine operation:

Computer numerical control software is used to operate fully automated CNC lathes. They can
easily position the X, Y, or Z axes and execute a variety of jobs, which is one of its key
advantages. These axes make it simple for the machine to move over the component in
accordance with its geometry, whether it be square, conical, spherical, etc. It is also capable of
working with a variety of materials and intricate pieces. Drilling, turning, milling, cutting, and
other industrial sector duties can be accomplished using this kind of equipment. This facilitates
the production of more precisely made parts in bigger quantities.[6]
3.1 Some basic parts of CNC lathe are
• Main Spindle: The primary spindle is made up of a spindle assembly and a spindle drive
system. These components are among the moving parts in the CNC machine tool and
consist of motors, gears, and the chuck. Furthermore, the C-axis drive, which assists in
positioning the material, will also be integrated with the spindle.
• Guide Way: It allows the tool to move both horizontally and vertically, facilitating a
smooth cutting operation.
• Chuck: A chuck is a device designed to secure the components being machined. It is
connected to the main spindle, which rotates both the chuck and the workpiece.
• Headstock: The headstock, which includes the main motor, houses the main spindle onto
which the chuck is attached..[6]
Fig 3.1: Various parts of CNC lathe machine

4
3.2 How CNC lathe machine removes material from workpiece:

The functioning of a CNC (Computer Numerical Control) lathe relies on the precise management
of the machine's movements and cutting tools through computer programming. Here’s a
breakdown of the essential process:
3.2.1 Input of CNC Program (G-Code)**: CNC lathes operate using a dedicated
programming language called G-code, which provides the machine with
necessary instructions, such as tool positioning, cutting speeds, feed rates, and
other parameters. Operators can write the G-code manually or use CAD/CAM
(Computer-Aided Design and Manufacturing) software to generate it.
3.2.2 Loading and Securing the Workpiece**: The workpiece, typically a cylindrical
piece of metal or other material, is securely clamped into the spindle chuck. The
spindle rotates the workpiece at the specified speed, which is controlled by the
CNC program depending on the requirements of the part being machined.
3.2.3 Cutting Tool Positioning and Tool Turret Operation**: A CNC lathe features a
tool turret with multiple cutting tools that can be shifted into position as needed.
The machine's computer system precisely manages the X (horizontal) and Z
(longitudinal) axes to accurately move the cutting tool based on the program’s
instructions. The machine automatically selects the appropriate tool for various
operations like turning, facing, drilling, or boring.
3.2.4 Material Removal Process**: As the workpiece rotates, the cutting tool follows a
predetermined path to remove material and shape the part. It executes a series of
programmed passes, beginning with rough cuts and progressing to finishing cuts,
to achieve the specified dimensions and surface quality. Key parameters such as
feed rate (the speed at which the tool engages with the material) and depth of cut
are governed by the CNC program.
3.2.5 Monitoring and Adjustments**: Throughout the machining process, the CNC
system continuously tracks the machine's parameters, including position, speed,
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and tool wear. Modern CNC lathes are equipped with sensors to identify and
correct problems, such as tool deflection or material inconsistencies, ensuring
ongoing accuracy.
3.2.6 Completion and Part Ejection**: When machining is finished, the spindle halts,
and the part is removed from the chuck, either automatically or manually. The
CNC program can be reused for producing multiple parts, enabling consistent and
repeatable manufacturing.
3.2.7 Various Types of Lathe Operations**: One such operation is knurling, which
creates a diamond-patterned surface on the workpiece, improving the grip of
machine parts and enhancing their appearance..[7]
Fig 3.3.1: Knurling operation [7]
3.2.8 Boring: In a boring operation, a tool penetrates the workpiece along its axis to
cut away material from the interior surface, either to form various shapes or to
increase the size of an existing hole.. [7]

6
Fig3.3.2: Boring operation [7]
3.2.9 Turning: Turning is the most common lathe machining operation. During the
turning process, a cutting tool removes material from the outer diameter of a
rotating workpiece. The main objective of turning is to reduce the workpiece
diameter to the desired dimension. There are two types of turning operations,
rough and finish. [7]
Fig 3.3.3: Turning Operation [7]
3.2.10 Facing: During the machining, the length of the workpieces is slightly longer
than the final part should be. Facing is an operation of machining the end of a
workpiece that is perpendicular to the rotating axis. During the facing, the tool
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moves along the radius of the workpiece to produce the desired part length and a
smooth face surface by removing a thin layer of material. [7]
Fig 3.3.4: Facing [7]
3.2.11 Drilling: Drilling operation removes the material from the inside of a workpiece.
The result of drilling is a hole with a diameter equal to the size of the utilized drill
bit. Drill bits are usually positioned either on a tailstock. [7]
Fig 3.3.5: Drilling [7]
3.2.12 Taper Turning: Taper turning produces a ramp transition between the two
surfaces with different diameters due to the angled motion between the workpiece
and a cutting tool. [7]
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Fig 3.3.6: Taper Turning [7]
3.2.13 Chamfering: Similar to the step turning, chamfer turning creates angled
transition of an otherwise square edge between two surfaces with different turned
diameters. [7]
Fig 3.3.7: Chamfering [7]
3.2.14 Reaming: Reaming is a sizing operation that enlarges the hole in the workpiece.
In reaming operations, reamer enters the workpiece axially through the end and
expands an existing hole to the diameter of the tool. Reaming removes a minimal
9
amount of material and is often performed after drilling to obtain both a more
accurate diameter and a smoother internal finish. [7]
Fig 3.3.9: Reaming [7]
3.2.15 Grooving: Grooving is a turning operation that creates a narrow cut, a “groove”
in the workpiece. The size of the cut depends on the width of a cutting tool.
Multiple tool passes are necessary to machine wider grooves. There are two types
of grooving operations, external and face grooving. In external grooving, a tool
moves radially into the side of the workpiece and removes the material along the
cutting direction. In face grooving, the tool machines groove in the face of the
workpiece. [7]
Fig 3.3.9: Grooving [7]
3.2.16 Threading: Threading is a turning operation in which a tool moves along the side
of the workpiece, cutting threads in the outer surface. A thread is a uniform helical
groove of specified length and pitch. Deeper threads need multiple passes of a
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tool. [7]
Fig 3.3.10: Threading [7]
3.2.17 Tapping: Tapping is the process in which a tapping tool enters the workpiece
axially and cuts the threads into an existing hole. The hole matches a
corresponding bit size that can accommodate the desired tapping tool. Tapping is
also the operation used to make a thread on nuts. [7]
Fig 3.3.11: Tapping [7]

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4.0 COMPREHENSIVE STUDY OF CNC LATHE MACHINE:

4.1 Software: Mastercam Software is a robust CAD (computer-aided design) and CAM
(computer-aided manufacturing) application utilized for designing and producing parts,
products, and toolpaths. It is extensively employed in the manufacturing sector,
particularly in aerospace, automotive, medical, and energy industries. As a premier
CAD/CAM solution, Mastercam delivers sophisticated design tools and machining
capabilities. This Windows-based application equips designers and engineers with a
complete suite of tools to create and manufacture intricate parts and products. Mastercam
is developed by CNC Software, Inc., based in Tolland, Connecticut, USA.[8]
➢ Features of Mastercam software: Mastercam provides a range of features that
contribute to its popularity as a CAD/CAM software in the industry. Below are
some of its key features:
➢ Advanced Design Tools: Mastercam provides designers with a wide range of
advanced design tools, including 2D and 3D modelling, surface modeling, solid
modeling, and more. These tools allow designers to create complex parts and
products with ease and precisionMastercam offers designers an extensive array
of advanced design tools, such as 2D and 3D modeling, surface modeling, solid
modeling, and additional features. These tools enable designers to effortlessly and
accurately create intricate parts and products.
➢ Intelligent Toolpaths: Mastercam offers intelligent toolpaths that help to reduce

machining time and improve surface finish. It includes high-speed machining,
dynamic milling, and other features that make the manufacturing process more
efficient. Mastercam provides advanced toolpaths designed to minimize
machining time and enhance surface quality. It encompasses high-speed
machining, dynamic milling, and various other functionalities that streamline the
manufacturing process.

12
➢ Multi-axis Machining: Mastercam offers multi-axis machining capabilities,

which allow for the creation of complex parts with multiple curves and angles. It
also supports 5-axis machining, which is used for machining parts with rotational
symmetry.
4.1.1 Applications of Mastercam software: The manufacturing industry widely uses

Mastercam, specifically in the areas of aerospace, automotive, medical, and
energy sectors. Here are some of the most common applications of Mastercam:
➢ Aerospace Industry: The aerospace industry uses Mastercam to create
complex parts and products, including airplane parts, spacecraft
components, and more.
➢ Automotive Industry: The automotive industry uses Mastercam to
design and manufacture parts and products, including engine parts,
transmissions, and more.
➢ Medical Industry: Mastercam is used to create medical devices,
including prosthetics, surgical instruments, and more.
➢ Energy Industry: The energy industry uses Mastercam to create parts
and products for the oil and gas sector, including drilling tools, valves,
and more.
➢ Mold Making: The mold-making industry uses Mastercam to create
molds for plastic injection molding, die casting, and more.
➢ Tool Making: The tool making industry uses Mastercam to create
cutting tools, fixtures, jigs, and more.

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4.1.2 Benefits of Mastercam software: Mastercam software offers several benefits to

designers and manufacturers, making it a popular choice in the industry. Here are
some of the most significant benefits of Mastercam:
➢ Precision and accuracy: Mastercam offers precision and accuracy in the
manufacturing process. For instance, the software provides designers with
tools that ensure parts and products are created to the exact specifications,
minimizing errors and improving quality.
➢ Increased efficiency: Mastercam offers intelligent toolpaths and advanced
design tools, which help to reduce machining time and increase
efficiency. In fact, this, in turn, reduces manufacturing costs and increases
productivity.
➢ Flexibility: Mastercam is a flexible CAD/CAM solution that can be used
for various manufacturing applications. Generally, the software can create
parts and products for a wide range of industries, including aerospace,
automotive, medical, and energy sectors.
➢ Cost effective: Mastercam is a cost-effective solution for designers and
manufacturers. In fact, the software’s advanced tools and features are
available at a reasonable price, making it accessible to small and medium-
sized businesses.

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References: (Date of access: 06-11-2024)

[1] "Types of CNC Machines and Their Applications." Volume 11, Issue 5, 2022.
[2] "CNC Machines: A Case Study and Its Analysis." Volume 4, Issue 5, 2022.
[3] "Study on CNC Machining Process and Technology." Volume 7, Issue 3, 2020.
[4] https://www.chevaliertw.com/en/products/FCL-18-21-25-30-32-40-Series#Features
[5] Machine Tool Practices. Prentice Hall,Roberts, L. (1998)
[6] https://3axis-group.com/how-does-cnc-lathe-machine-work/
[7] https://turntechprecision.com/machining-operations-performed-on-a-lathe
[8] https://qtemfg.com/what-is-mastercam-software/

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Khulna University of Engineering & Technology

Course no: ME 4208

Date of performance: 28-10-24 Name: Suvojit Baidya

Report on ME-4208 by Suvojit Baidya (1905041), Department of Mechanical Engineering, KUET

Fig 1.0: CNC lathe machine [4]

The main objective of the study of CNC lathe machines are,

Report on ME-4208 by Suvojit Baidya (1905041), Department of Mechanical Engineering, KUET

3.0 Principle of CNC lathe machine operation:

Fig 3.1: Various parts of CNC lathe machine

Report on ME-4208 by Suvojit Baidya (1905041), Department of Mechanical Engineering, KUET

3.2 How CNC lathe machine removes material from workpiece:

Fig 3.3.1: Knurling operation [7]

Report on ME-4208 by Suvojit Baidya (1905041), Department of Mechanical Engineering, KUET

Fig3.3.2: Boring operation [7]

Fig 3.3.3: Turning Operation [7]

Fig 3.3.4: Facing [7]

Fig 3.3.5: Drilling [7]

Fig 3.3.6: Taper Turning [7]

Fig 3.3.7: Chamfering [7]

Fig 3.3.9: Reaming [7]

Fig 3.3.9: Grooving [7]

Fig 3.3.10: Threading [7]

Fig 3.3.11: Tapping [7]

Report on ME-4208 by Suvojit Baidya (1905041), Department of Mechanical Engineering, KUET

4.0 COMPREHENSIVE STUDY OF CNC LATHE MACHINE:

➢ Intelligent Toolpaths: Mastercam offers intelligent toolpaths that help to reduce

Report on ME-4208 by Suvojit Baidya (1905041), Department of Mechanical Engineering, KUET

➢ Multi-axis Machining: Mastercam offers multi-axis machining capabilities,

4.1.1 Applications of Mastercam software: The manufacturing industry widely uses

Report on ME-4208 by Suvojit Baidya (1905041), Department of Mechanical Engineering, KUET

4.1.2 Benefits of Mastercam software: Mastercam software offers several benefits to

Report on ME-4208 by Suvojit Baidya (1905041), Department of Mechanical Engineering, KUET

References: (Date of access: 06-11-2024)

Report on ME-4208 by Suvojit Baidya (1905041), Department of Mechanical Engineering, KUET

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