INTERNSHIP REPORT

Submitted by
GOWTHAM J-61772151L04

In partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT COLLEGE OF ENGINEERING, SALEM-11

(AICTE Approved, NAAC accredited, Autonomous Institution Affiliated to Anna University,
Chennai)

I
 GOVERNMENT COLLEGE OF ENGINEERING
SALEM-11.
(An Autonomous Institution, Affiliated to Anna University, Chennai)

BONAFIDE CERTIFICATE

This is to certify that this Internship training programme report based on

industrial training undergone at SHANMUGA CNC, KSR NAGAR, AMBATTUR,
CHENNAI-600053 from 15 JUNE 2023 to 13 JULY 2023 this report done by GOWTHAM J
of B.E Mechanical Engineering.

DATE: SIGNATURE
Dr. T. BALUSAMY, Ph.D.,
Head of the Department,
Department of Mechanical
Engineering,
Government College of Engineering,
Salem - 11
Report submitted for the internal evaluation of Internship Programme on
.

EXAMINER 1 EXAMINER 2
II
III
 ACKNOWLEDGEMENT

I take immense pleasure in thanking my beloved Principal

Dr. R. MALAYALAMURTHI, Ph.D., for the encouragement to progress and completion of
the training.

It is my great pleasure and deep sense of gratitude to our professor and Head of the
Department Dr. T. BALUSAMY, Ph.D., for the inspiring guidance and whole hearted
encouragement and direction.

I wish to express my sincere gratitude to my Faculty Advisor, Dr. D. LAVANYA, Ph.D.,

Assistant Professor, Department of Mechanical Engineering, for her valuable in helping us to
complete the training successfully.

I would like to express my gratitude towards various Departments Managers,

Supervisors Engineers and Workers of SHANMUGA CNC, KSR NAGAR, AMBATTUR,
CHENNAI-600053 for explaining about industry concept and importance of each department,
CNC and EDM with their patience and openness they created an enjoyable listening
environment.

My sincere thanks and gratitude are extended humbly to all the teaching faculty of
Mechanical Engineering Department, Government College of Engineering, Salem for the
contribution towards the successful completion of the internship training programme.

I am extremely great full to friends who helped me in successful completion of this

internship.

IV
 TABLE OF CONTENTS

CHAPTER DESCRIPTION PAGE NO

LIST OF FIGURES VI
I INTRODUCTION X
II WIRE CUT EDM
2.1 INTRODUCTION OF EDM 2
2.2 HISTORY 2
2.3 MATERIAL REMOVAL MECHANISM 3
2.4 TYPES OF EDM 4
2.5 APPLICATIONS 6
III CNC, HMC AND VMC
3.1 STUDY ON CNC, VMC AND HMC MACHINE 7
3.2 G CODES AND M CODES 8
3.3 HMC MACHINE 8
3.4 VMC MACHINE 9
3.5 VMC MACHINING 10
IV TOOLING
4.1 INTRODUCTION TO TOOLING 12
4.2 TOOL CODING 14
VI CONCLUSION 18

V
 LIST OF FIGURES

FIGURE FIGURE NAME PAGE

NO NO
2.1 CNC wire-cut EDM Machine 5
2.2 Schematic of CNC wire-cut EDM Machine 5
3.1 CNC Machine 8
3.2 HMC Machine 8
3.3 VMC Machine 9
4.1 General Turning Insert Nomenclature 14
4.2 General Turning Insert Nomenclature Shape 15
4.3 General Turning Insert Nomenclature Clearance-Angle 15
4.4 General Turning Insert Type 16
4.5 General Turning Insert Cutting Edge Length 17
4.6 General Turning Insert Nose Radius 17

VI
 CHAPTER I
INTRODUCTION
Internships are generally thought of to be reserved for college students looking to gain
experience in a particular field. However, a wide array of people can benefit from Training
Internships in order to receive real world experience and develop their skills.

An objective for this position should emphasize the skills you already possess in the
area and your interest in learning more

Internships are utilized in a number of different career fields, including architecture,

engineering, healthcare, economics, advertising and many more.

Some internship is used to allow individuals to perform scientific research while

others are specifically designed to allow people to gain first-hand experience working.

Utilizing internships is a great way to build your resume and develop skills that can be
emphasized in your resume for future jobs. When you are applying for a Training Internship,
make sure to highlight any special skills or talents that can make you stand apart from the
rest of the applicants so that you have an improved chance of landing the position.

X
 CHAPTER II
EDM WIRE CUT
2.1 INTRODUCTION OF EDM
Electrical discharge machining (EDM), also known as spark machining, spark
eroding, die sinking, wire burning or wire erosion, is a metal fabrication process
whereby a desired shape is obtained by using electrical discharges (sparks).[1] Material is
removed from the work piece by a series of rapidly recurring current discharges between
two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the
electrodes is called the tool-electrode, or simply the tool or electrode, while the other is
called the workpiece-electrode, or work piece. The process depends upon the tool and work
piece not making physical contact. When the voltage between the two electrodes is
increased, the intensity of the electric field in the volume between the electrodes becomes
greater, causing dielectric break down of the liquid, and produces an electric arc. As a
result, material is removed from the electrodes. Once the current stops (or is stopped,
depending on the type of generator), new liquid dielectric is conveyed into the inter-
electrode volume, enabling the solid particles (debris) to be carried away and the insulating
properties of the dielectric to be restored. Adding new liquid dielectric in the inter-electrode
volume is commonly referred to as flushing. After a current flow, the voltage between the
electrodes is restored to what it was before the breakdown, so that a new liquid dielectric
breakdown can occur to repeat the cycle.
2.2 HISTORY
Die-sink EDM
Two Russian scientists, B. R. Lazarenko and N. I. Lazarenko, were tasked in 1943 to
investigate ways of preventing the erosion of tungsten electrical contacts due to sparking.
They failed in this task but found that the erosion was more precisely controlled if the
electrodes were immersed in a dielectric fluid. This led them to invent an EDM machine
used for working difficult-to-machine materials such as tungsten. The Lazarenkos' machine
is known as an R-C-type machine, after the resistor–capacitor circuit (RC circuit) used to
charge the electrodes. Simultaneously but independently, an American team, Harold Stark,
Victor Harding, and Jack Beaver, developed an EDM machine for removing broken drills
and taps from aluminium castings. Initially constructing their machines from under-
powered electric-etching tools, they were not very successful. But more powerful sparking
units, combined with automatic spark repetition and fluid replacement with an
electromagnetic interrupter arrangement produced practical machines. Stark, Harding, and
Beaver's machines were able to produce 60 sparks per second. Later machines based on
their design used vacuum tube circuits that were able to produce thousands of sparks per
second, significantly increasing the speed of cutting.
Wire-cut EDM
The wire-cut type of machine arose in the 1960s for making tools (dies) from
hardened steel. The tool electrode in wire EDM is simply a wire. To avoid the erosion of
the wire causing it to break, the wire is wound between two spools so that the active part of
the wire is constantly changing. The earliest numerical controlled (NC) machines were
conversions of punched-tape vertical milling machines. The first commercially available
NC machine built as a wire-cut EDM machine was manufactured in the USSR in 1967.

2
Machines that could optically follow lines on a master drawing were developed by David H.
Dulebohn's group in the 1960s at Andrew Engineering Company for milling and grinding
machines. Master drawings were later produced by computer numerical controlled (CNC)
plotters for greater accuracy. Feed rates have increased and surface finish can be finely
controlled.
2.3 MATERIAL REMOVAL MECHANISM
The first serious attempt at providing a physical explanation of the material removal
during electric discharge machining is perhaps that of Van Dijck. Van Dijck presented a
thermal model together with a computational simulation to explain the phenomena between
the electrodes during electric discharge machining. However, as Van Dijck himself
admitted in his study, the number of assumptions made to overcome the lack of
experimental data at that time was quite significant.
Further models of what occurs during electric discharge machining in terms of heat
transfer were developed in the late eighties and early nineties. It resulted in three scholarly
papers: the first presenting a thermal model of material removal on the cathode, the second
presenting a thermal model for the erosion occurring on the anode and the third introducing
a model describing the plasma channel formed during the passage of the discharge current
through the dielectric liquid. Validation of these models is supported by experimental data
provided by AGIE.
These models give the most authoritative support for the claim that EDM is a thermal
process, removing material from the two electrodes because of melting or vaporization,
along with pressure dynamics established in the spark-gap by the collapsing of the plasma
channel. However, for small discharge energies the models are inadequate to explain the
experimental data. All these models hinge on a number of assumptions from such disparate
research areas as submarine explosions, discharges in gases, and failure of transformers, so
it is not surprising that alternative models have been proposed more recently in the
literature trying to explain the EDM process.
Among these, the model from Singh and Ghosh reconnects the removal of material from
the electrode to the presence of an electrical force on the surface of the electrode that could
mechanically remove material and create the craters. This would be possible because the
material on the surface has altered mechanical properties due to an increased temperature
caused by the passage of electric current. The authors' simulations showed how they might
explain EDM better than a thermal model (melting or evaporation), especially for small
discharge energies, which are typically used in μ-EDM and in finishing operations. Given
the many available models, it appears that the material removal mechanism in EDM is not
yet well understood and that further investigation is necessary to clarify it, especially
considering the lack of experimental scientific evidence to build and validate the current
EDM models. This explains an increased current research effort in related experimental
techniques. In this conclusion, there are following major factors are achieved during
machining operations:
Resulting foremost conclusions can be stated from review of work in this area that
EDM performance is generally evaluated on the basis of TWR, MRR, Ra and hardness.

3
 In material removal rate (MRR) from all selected parameters, spark current (I) is the
most significant input factor affecting the machining of workpiece.
The performance is affected by discharge current, pulse on time, pulse off time, duty
cycle, voltage for EDM.
For tool wear rate (TWR) from the all selected parameters, spark current (I) is the most
significant input factor affecting the machining of workpiece followed by spark time
and voltage.
Innovative technology in the EDM is unceasingly progressing to make this procedure
further appropriate for the Machining. In the field of manufacturing additional attention
is on the optimization of the method by dropping the number of Electrode.
2.4 TYPES OF EDM
Sinker EDM
Sinker EDM allowed quick production of 614 uniform injectors for the J-2 rocket
engine, six of which were needed for each trip to the moon. Sinker EDM, also called ram
EDM, cavity type EDM or volume EDM, consists of an electrode and workpiece
submerged in an insulating liquid such as, more typically, oil or, less frequently, other
dielectric fluids. The electrode and workpiece are connected to a suitable power supply.
The power supply generates an electrical potential between the two parts. As the electrode
approaches the workpiece, dielectric breakdown occurs in the fluid, forming a plasma
channel, and a small spark jumps. These sparks usually strike one at a time. because it is
very unlikely that different locations in the inter-electrode space have the identical local
electrical characteristics which would enable a spark to occur simultaneously in all such
locations. These sparks happen in huge numbers at seemingly random locations between
the electrode and the workpiece. As the base metal is eroded, and the spark gap
subsequently increased, the electrode is lowered automatically by the machine so that the
process can continue uninterrupted. Several hundred thousand sparks occur per second,
with the actual duty cycle carefully controlled by the setup parameters. These controlling
cycles are sometimes known as "on time" and "off time", which are more formally defined
in the literature. The on time setting determines the length or duration of the spark. Hence,
a longer on time produces a deeper cavity from each spark, creating a rougher finish on the
workpiece. The reverse is true for a shorter on time. Off time is the period of time between
sparks. Although not directly affecting the machining of the part, the off time allows the
flushing of dielectric fluid through a nozzle to clean out the eroded debris. Insufficient
debris removal can cause repeated strikes in the same location which can lead to a short
circuit. Modern controllers monitor the characteristics of the arcs and can alter parameters
in microseconds to compensate. The typical part geometry is a complex 3D shape,often
with small or odd shaped angles. Vertical, orbital, vectorial, directional, helical, conical,
rotational, spin and indexing machining cycles are also used.

4
Wire EDM

Figure 2.1 CNC wire-cut EDM Machine

Figure 2.2 Schematic of CNC wire-cut EDM Machine

1. Wire 2. Electrical discharge Erosion 3. Electrical Potential 4. Workpiece

In wire electrical discharge machining (WEDM), also known as wire-cut

EDM and wire cutting, a thin single-strand metal wire, usually brass, is fed through the
workpiece, submerged in a tank of dielectric fluid, typically deionized water. Wire-cut
EDM is typically used to cut plates as thick as 300mm and to make punches, tools, and dies
from hard metals that are difficult to machine with other methods. The wire, which is
constantly fed from a spool, is held between upper and lower diamond guides which is
centered in a water nozzle head. The guides, usually CNC-controlled, move in the x–
y plane. On most machines, the upper guide can also move independently in the z–u–v axis,
giving rise to the ability to cut tapered and transitioning shapes (circle on the bottom,
square at the top for example). The upper guide can control axis movements in the GCode
standard, x–y–u–v–i–j–k–l–. This allows the wire-cut EDM to be programmed to cut very
intricate and delicate shapes. The upper and lower diamond guides are usually accurate to
0.004 mm (0.16 mils), and can have a cutting path or kerf as small as 0.021 mm (0.83 mils)
using Ø 0.02 mm (0.79 mils) wire, though the average cutting kerf that achieves the best
economic cost and machining time is 0.335 mm (13.2 mils) using Ø 0.25 mm (9.8 mils)
brass wire. The reason that the cutting width is greater than the width of the wire is because
sparking occurs from the sides of the wire to the work piece, causing erosion.[28] This
"overcut" is necessary, for many applications it is adequately predictable and therefore can
5
be compensated for (for instance in micro-EDM this is not often the case). Spools of wire
are long — an 8 kg spool of 0.25 mm wire is just over 19 kilometers in length. Wire
diameter can be as small as 20 μm (0.79 mils) and the geometry precision is not far from ±
1 μm (0.039 mils).
Fast hole drilling EDM
Fast hole drilling EDM was designed for producing fast, accurate, small, and deep
holes. It is conceptually akin to sinker EDM but the electrode is a rotating tube conveying a
pressurized jet of dielectric fluid. It can make a hole an inch deep in about a minute and is a
good way to machine holes in materials too hard for twist-drill machining. This EDM
drilling type is used largely in the aerospace industry, producing cooling holes into aero
blades and other components. It is also used to drill holes in industrial gas turbine blades, in
molds and dies, and in bearings.
Prototype production
The EDM process is most widely used by the mold-making, tool, and die industries,
but is becoming a common method of making prototype and production parts, especially in
the aerospace, automobile and electronics industries in which production quantities are
relatively low. In sinker EDM, a graphite, copper tungsten, or pure copper electrode is
machined into the desired (negative) shape and fed into the workpiece on the end of a
vertical ram.

2.5 APPLICATIONS

The wire EDM machine, also known as a “cheese cutter,” offers several unique
advantages, making it a popular choice for manufacturers across a range of different
industries.

EDM Benefits

Wire EDM machines are able to carefully remove excess material without exerting a
strong cutting force. The process is often automated, meaning it has less chance of causing
damage to the workpiece itself. And because wire EDM machines can accommodate hard
materials, there is no need for secondary, post-machining thermal treatments. As a result,
there is little to no heat stress placed on the shaped part, and less chance that the surface of
the part will become distorted.

EDM Applications

Wire EDM is most commonly used in mold and die manufacturing processes,
particularly for extrusion dies and blanking punches. EDM can be used in everything from
prototypes to full production runs, and is most often used to manufacture metal components
and tools. The process is best suited for applications requiring low levels of residual stress.

EDM Industries

EDM is most commonly used to manufacture parts and components for the automotive,
aerospace, and electronics industries.
6
 CHAPTER III
CNC, VMC AND HMC
3.1 STUDY ON CNC, VMC AND HMC MACHINE
The term CNC stands for 'computer numerical control', and the CNC machining
definition is that it is a subtractive manufacturing process that typically employs
computerized controls and machine tools to remove layers of material from a stock piece—
known as the blank or work piece—and produces a custom-designed part. This process is
suitable for a wide range of materials, including metals, plastics, wood, glass, foam, and
composites, and finds application in a variety of industries, such as large CNC machining,
machining of parts and prototypes for telecommunications, and CNC machining aerospace
parts, which require tighter tolerances than other industries. Note there is a difference
between the CNC machining definition and the CNC machine definition- one is a process
and the other is a machine. A CNC machine (sometimes incorrectly referred to as a C and
C machine) is a programmable machine that is capable of autonomously performing the
operations of CNC machining.
Subtractive manufacturing processes, such as CNC machining, are often presented in
contrast to additive manufacturing processes, such as 3D printing, or formative
manufacturing processes, such as liquid injection molding. While subtractive processes
remove layers of material from the work piece to produce custom shapes and designs,
additive processes assemble layers of material to produce the desired form and formative
processes deform and displace stock material into the desired shape. The automated nature
of CNC machining enables the production of high precision and high accuracy, simple
parts and cost-effectiveness when fulfilling one-off and medium-volume production runs.
However, while CNC machining demonstrates certain advantages over other manufacturing
processes, the degree of complexity and intricacy attainable for part design and the cost-
effectiveness of producing complex parts is limited.
The basic CNC machining process includes the following stages:
1. Designing the CAD model
2. Converting the CAD file to a CNC program
3. Preparing the CNC machine
4. Executing the machining operation
\Mechanical CNC machining operations :
1) Drilling
2) Milling
3) Turning

Fig. No 3.1 CNC Machine

7
3.2 G CODES AND M CODES
G code commands tend to differ in most CNC machines, while M codes are similar
in most CNC machines. G codes direct the machine's motion and function, while M codes
direct the operations outside movements. The G code activates the CNC machine while the
M code activates the machine's programmable logic controller.

G Codes and M Codes for Milling

G Code List for CNC Milling M Codes for CNC Milling

G00: Rapid Motion M00: Program Stop

G01: Linear Interpolation Motion M01: Optional Program Stop
G02: CW Interpolation Motion M02: Program End (Setting 39)
G03: CCW Interpolation Motion M03: Spindle On, Clockwise (S)
G04: Dwell M04: Spindle On, Counterclockwise
G09: Exact Stop (S)\
G10: Programmable Offset Setting M05: Spindle Stop
G12: CW Circular Pock Milling M06: Tool Change (T)
G13: CCW Circular Pock Milling M08: Coolant On
G17: XY Plane Selection M09: Coolant Off
M10: 4th Axis Brake On

3.3 HMC MACHINE

Horizontal machining center (HMC) is a machining center with its spindle in a horizontal
orientation. This machining center design favors uninterrupted production work. One
reason for this is that the horizontal orientation encourages chips to fall away, so they don’t
have to be cleared from the table. More significantly, the horizontal design allows a two-
pallet workchanger to be incorporated into a space-efficient machine. To save time, work
can be loaded on one pallet of a horizontal machining center while machining occurs on the
other pallet.
A HMC provides a stiffer machine platform than a VMC because of spindle
orientation. In a HMC, the spindle is located inside the column, and on a C-frame VMC, it
is cantilevered away from the columnover the worktable and base.

Fig. No 3.2 HMC Machine

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3.4 VMC MACHINE

VMC machining refers to machining operations that utilize vertical machining

centers (VMCs), which, as the name suggests, have vertically oriented machine tools.
These machines are primarily utilized to turn raw blocks of metal, such as aluminum or
steel, into machined components. In VMC Machine we can do Drilling, Facing, Turning
operations. In CNC Machines the job is rotating one tool will not rotate during machining
period whereas in VMC and HMC tool will rotate and Works piece is stable.
A VMC uses cutters to remove me tal from a work piece and employs a vertical spindle.
Because of that vertical orientation, a VMC's tools typically work in a vertical work plane.
HMCs employ a spindle that runs on a horizontal work plane and uses cutting tools to
remove metal from the work piece.

Fig.No 3.3 VMC Machine

9
3.5 VMC MACHINING

VMC machining refers to machining operations that utilize vertical machining centers
(VMCs), which, as the name suggests, have vertically oriented machine tools. These
machines are primarily utilized to turn raw blocks of metal, such as aluminum or steel, into
machined components. They can be used to perform a variety of machining operations,
including, but not limited to, the following: cutting, drilling, tapping, countersinking,
chamfering, carving, and engraving. This versatility, combined with their relatively low
cost, has made them a highly common machine shop tool.

Advantages of VMC Machining

Compared to horizontal machining centers, vertical machining centers offer a number of

advantages, such as:

Simpler structure. The simple structure of VMCs makes it easy to clamp the work
piece in the necessary position.

Better cooling efficiency. Gravity works with the VMC design. Coolant sprayed at the
top of the machine tool and work piece trickles down to cover the rest of the target.

Easier setup and operation. VMCs have a wide field of vision, enabling operators to
observe the operations and, if needed, make modifications to resolve any issues.

Smaller space requirements. The vertical design takes up less floor space than a
horizontal design.

Higher accuracy. VMCs can produce complex shapes and structures with a high degree
of accuracy.

Applications of VMC Machining

Vertical machining centers can be used to manufacture parts and products for a wide range
of industries and applications. However, they are primarily used for high-precision, high-
accuracy, and mass-production projects, including those involving the following machined
components:

Complex curved parts. Examples of parts with complex curves include cams,
impellers, and propellers. While these parts are difficult to manufacture with precision and
accuracy using conventional machining methods, a multi-axis VMC with CNC technology
can produce them easily and quickly.

10
 Special or irregularly shaped parts. Examples of parts with irregular or special shapes
include brackets and bases. These components often have highly complex designs, which
are hard to produce using other manufacturing methods but easy to produce using VMCs
with automatic machining capabilities.

Military parts. The military industry is subjected to a variety of standards that dictate
how a part can be designed and built. The accuracy and precision of VMCs ensure the
machined components produced fully meet the necessary application and industry
specifications.

VMC Machining Services at FZE Manufacturing

Vertical machining is critical to the manufacture of a wide range of components for

various industries and applications. It offers many advantages over horizontal machining,
such as easier setup and operation, better cooling efficiency, and smaller space
requirements, which make it better suited for particular manufacturing projects.

Looking for a vertical machining service provider for your next manufacturing
project? The experts at FZE Manufacturing have got you covered! We are a full-service
manufacturing and machine shop offering a broad selection of machining capabilities.
From VMC machining to HMC machining to Swiss machining, we utilize our extensive
manufacturing experience and expertise to produce high-quality machined parts and
products.

11
 CHAPTER IV
TOOLING
4.1 INTRODUCTION TO TOOLING
Since ancient times, cutting tools have existed. They’re one of the oldest inventions
in human history and there has been a dramatic change in the type of cutting tools we use.
Initially, we built them with stones, so these metallic tools are of much value in the
manufacturing world.
Although all cutting tools serve one purpose, to cut through a material, there is a huge
difference in their purpose.
Normally, for a cutting tool to be effective, it has to:

• be 30% to 50% harder than the material it will work on.

• be easily fabricated.
• have high thermal conductivity.
• have low coefficient of friction.
• be very resistance to wear.
• be chemically inert and stable.

In practice, different CNC cutting tools perform cutting operations. Before

considering which CNC cutting tools to use for a specific operation, you’ve got to
understand the material that manufacturers used when producing the tool. Based on that
material, we classify cutting tools into:

Carbon Steel Tool

These cutting tools are inexpensive and are mainly for low-speed operations. They
have a carbon composition of 0.6 – 1.5% with a little amount of manganese and silicon.
They’re mainly in twist drills, forming tools, milling cutters, and turning.

High-Speed Steel (HSS)

It‘s composed of high carbon steel with a reasonable amount of element alloys like
chromium, tungsten, and molybdenum. With this combination, it improves hardness, wear
resistance, and toughness. It also offers higher removal rate for metals and other materials.
To improve its property, you’ve got to apply certain surface treatment.

Ceramics
These chemically inert tools are corrosion-resistant and 10x faster than high-speed
steel. Usually aluminum oxide and silicon nitride make up ceramics materials. Projects that
require top-notch finish operations normally use ceramics.

Cemented Carbide
Designed for high-speed operations, these carbide tools are extraordinarily hard and
can withstand temperatures of up to 1000oC. Normally, tantalum, titanium, and tungsten
make them up. Operations that require a high-quality surface finish also use them.
Other classifications include diamond tools, cubic boron nitride (CBN), sialon, and cermets.
12
CNC Cutting tools come in various shapes and sizes and you can use them for various
milling and lathe cutting operations.

Some CNC cutting tools are:

End Mills
Rotational cutting tools that you can use for the removal of materials. Although very
similar to the drill bit, the end mill is for more versatile machining operations. Unlike the
drill bit that cut axially to the material, end mills are lateral cutting tools that cut in any
direction. Due to their design, some end mills cannot cut materials axially. Generally, there
are different types of tip shapes for an end mill and each end mill depends on the desired
end-product. The various types of end mills are:

Ball nose mills: Ideal for 3D contour work, ball nose mills have rounded ends that produce
top-notch curved surfaces.

V- bit: Depressions that these tools make are V-shaped. V-bit can be 90o or 60o and each
depends on the angle of depression that a material needs. Although they often use them to
engrave signs on materials, they’re ideal for projects that need excellent sharp edges.

Straight Flute End Mills: These CNC cutting tools are general purpose tools that offer top
quality edges.
Down-cut and up-cut end mills: These spiral tools can either produce a smooth-surface
finish by carrying the residue chips down or a rough-surface finish by carrying the residue
up and away from the specified area.

Twist Drills: These rotary CNC cutting tools have two flutes and two cutting edges.
Through their unique designs, coolants can quickly reach the point of cut action.
Manufacturers usually use these cutting tools to lower production costs and perform
operations with top-notch finishing.
The twist drill is comprised of three major parts: The shank, the body, and the point.

Fly Cutter: These single point cutters are on a mill and general purpose fly cutters provide
excellent surface finishes. This CNC cutting tool goes across the surface of a material
through a clockwise rotation, making the material surface smooth and flat. The fly cutter is
for CNC who want to produce an outstanding fine finish.

Cutting Fluids and Coolants: Typically, not a CNC cutting tool, cutting fluids flush
material chips away from the cutting zone. They also offer additional benefits like:
Reduction of thermal deformation in a work piece.

• Improvement of the tool life.

• Surface finish improvement.

13
 Tool holders typically hold CNC cutting tools before fitting them into the CNC
machines. The quality, design, and manufacturer’s specifications about the tool holders are
critical to an overall success of the machining operations.

Why Should You Make The Right Choice with CNC Cutting Tools?
Cutting tools play a vital role in the quality of projects done. Although buying these
items might be pricey, you cannot overlook their importance. In fact, the quality of your
project depends on the kind of cutting tool you use. The industrial world is highly
competitive and, to succeed, manufacturers and end-users have to build top-notch products
through proper planning and precise cutting. Since cutting tools form the backbone of a
professional project, you need to pay special attention to these little items that can make or
mar your projects. Greater productivity, high precision, accuracy, and efficiency in
machining operations are the driving force needed to craft top-notch products. You can
easily achieve these features by having the right cutting tools and having an in-depth
knowledge about CNC cutting tools is the first step towards success in a competitive
industry.

4.2 TOOL CODING

General turning inserts come in variety of shapes and sizes. One thing is important to
remember and understand is that every turning insert has a nomenclature associated with it.
These general turning inserts nomenclature tells us lot about these general turning inserts.
The turning inserts nomenclature is a list of some letters and numbers, but lot more data is
hidden inside them.

Fig No 4.1 General Turning Insert Nomenclature

The above turning insert nomenclature is CNMG 120408.
• 1 = Turning Insert Shape
• 2 = Turning Insert Clearance Angle
• 3 = Turning Insert Tolerances
• 4 = Turning Insert Type
• 5 = Turning Insert Size
• 6 = Turning Insert Thickness
• 7 = Turning Insert Nose Radius
1 = Turning Insert Shape
The first letter in general turning insert nomenclature tells us about the general
turning insert shape, turning inserts shape codes are like C, D, K, R, S, T, V, W. Most of
these codes surely express the turning insert shape like

14
 Fig No 4.2 General Turning Insert Nomenclature Shape
C = C Shape Turning Insert D = D Shape Turning Insert
K = K Shape Turning Insert R = Round Turning Insert
S = Square Turning Insert T = Triangle Turning Insert
V = V Shape Turning Insert W = W Shape Turning Insert

The general turning insert shape play a very important role when we choose an insert
for machining. Not every turning insert with one shape can be replaced with the other for a
machining operation. As C, D, W type turning inserts are normally used for roughing or
rough machining. As a CNC machinist I will use C type turning insert with Roughing
Cycle (G71 G72 for Fanuc cnc control), And I will choose D type turning insert for
Finishing Cycle(G70 for Fanuc ).

2 = Turning Insert Clearance Angle

Fig No 4.3 General Turning Insert Nomenclature Clearance-Angle

The second letter in general turning insert nomenclature tells us about the turning insert
clearance angle.
The clearance angle for a turning insert is given as
B = Turning Insert with 5° clearance angle
C = Turning Insert with 7° clearance angle
E = Turning Insert with 20° clearance angle
N = Turning Insert with 0° clearance angle
P= Turning Insert with 11° clearance angle

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 Turning insert clearance angle plays a big role while choosing an insert for internal
machining or boring small components, because if not properly chosen the insert bottom
corner might rub with the component which will give poor machining. On the other hand a
turning insert with 0° clearance angle is mostly used for rough machining.
3 = Turning Insert Tolerances
The third letter of general turning insert nomenclature tells us about the turning insert
tolerances. These are the turning insert tolerances in different insert sizes, like the tolerance
in turning insert length, height etc. I personally think that they are not of any use for a cnc
machinist, because theses tolerances are minor.
4 = Turning Insert Type
The fourth letter of general turning insert nomenclature tells us about the turning insert hole
shape and chip breaker type.

Fig No 4.4 General Turning Insert Type

A = Turning insert with Cylindrical hole

G = Turning insert with Cylindrical hole and Double-Sided Chipbreaker
M = Turning insert with Cylindrical hole and Single-Sided Chipbreaker
N = Turning insert with no hole and no Chipbreaker
P = Turning insert with Cylindrical hole and Hi-Double-Positive Chipbreaker
Q = Turning insert with 40-60° Double Countersink Hole
R = Turning insert with no-hole and Single-Sided Chipbreaker
T = Turning insert with 40-60° Double Countersink Single-sided Chipbreaker
W = Turning insert with 40-60° double countersink
X = Turning insert with Special Design
5 = Turning Insert Size
This numeric value of general turning insert tells us the cutting edge length of the turning
insert.
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 Fig No 4.5 General Turning Insert Cutting Edge Length

6 = Turning Insert Thickness

This numeric value of general turning insert tells us about the thickness of the
turning insert.
7 = Turning Insert Nose Radius

Fig No 4.6 General Turning Insert Nose Radius

This numeric value of general turning insert tells us about the nose radius of the turning
insert.
Code = Radius Value
04 = 0.4
08 = 0.8
12 = 1.2
16 = 1.6

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 CHAPTER V
CONCLUSION
The internship is a bridge between the theoretical knowledge and the practical or
reality work at the field of Industry. The responsibilities of the hosting company are to
each students and shape them in the one month as real industry person. Our company
Manager and Workers helped me take the internship session in their company in acquiring
different knowledge about valve machining and assembly.
We have learned about VMC Machining, EDM machining, Tooling. The most interesting
art of my internship program was the atmosphere we were done suitable.
Some of the benefits that we gain due to internship program are
Practical skills
Upgrading of theoretical knowledge and able to use it for practical work.
Developing of communication skills
Developing skill of team work
Improving personal ethics and knowing work ethics
Being able to do different tasks.

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