advance machining report
TRANSCRIPT
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1. INTRODUCTION
Computer Numerical Control (CNC) Milling is the most common form of CNC. CNC
mills can perform the functions of drilling and often turning. CNC Mills are classified
according to the number of axes that they possess. Axes are labelled as x and y for horizontal
movement, and z for vertical movement. CNC milling machines are traditionally
programmed using a set of commands known as G-codes. G-codes represent specific CNC
functions in alphanumeric format. During CNC milling, the computer translates the design
into instructions on how the drill needs to move to create the shape. Typically, the drill can
move up down, or tilt at an angle, and the table moves the part laterally. For complex parts,
the part may need to be rotated at some point in the milling process. Because the process is
run by a computer, high resolutions, and greater throughput are possible.
2. RAW MATERIALS
All cutters that are used in milling can be found in a variety of materials, which will
determine the cutter's properties and the workpiece materials for which it is best suited. These
properties include the cutter's hardness, toughness, and resistance to wear. Milling can be
performed on workpiece in variety of materials, including most metals and plastics. The
materials that are used in this milling is aluminium alloy 2024. Aluminium alloy 2024 is an
aluminium alloy, with copper as the primary alloying element. It is used in applications
requiring high strength to weight ratio, as well as good fatigue resistance. It is wieldable only
through friction welding, and has average machinability. This material has a dimension of
100mm x 100mm x 26mm and weight of 2 kg.
Figure 2.1 Material use; Aluminium Alloy 2024
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3. PROCESS TOOLS
Milling cutters are cutting tools typically used in milling machines or machining
centres to perform milling operations. They remove material by their movement within the
machine or directly from the cutter's shape. Milling cutters come in several shapes and many
sizes. There is also a choice of coatings, as well as rake angle and number of cutting surfaces.
Cutting tool in CNC milling such as flat End mill, counter drill, drill, face mill, slab mill,
counter bore, and countersank.
Figure 3.1 Milling cutter tools
i. End milling-An end mill makes either peripheral or slot cuts,-determined by the step-over distance, across the workpiece in order to machine
specified feature, such as a profile, slot, pocket, or even a complex surface contour.
Figure 3.2 End Mill Toolpath
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ii. Drilling-A drill enters the workpiece axially and cuts a hole with a diameter equal to that
of the tool.
-produce a blind hole, which extends to some depth inside the workpiece, or a
through hole which extends completely through the workpiece.
Figure 3.2 Drilling Toolpath
iii. Chamfer milling- A chamfer end mill makes a peripheral cut along an edge of the workpiece or
a feature to create an angled surface.
-A 45 degree angle, can be machined on either the exterior or interior of a part
and can follow either a straight or curved path.
iv. Face milling-A face mill machines a flat surface of the workpiece in order to provide a
smooth finish.
-The depth of the face, typically very small, may be machined in a single pass
or may be reached by machining at a smaller axial depth of cut and making
multiple passes.
Figure 3.3 Chamfer Mill Toolpath Figure 3.2 Face Mill Toolpath