manufacturing process article · and input it on swansoft cnc simulator. 6. create nc code for...

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MANUFACTURING PROCESS

ARTICLE

2019

By: Rino Andias Anugraha and Assistant Team

School of Industrial Engineering

TelkomUniversity

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INTRODUCTION

Praise be to Allah Subhanahu wa Ta'ala, because with His grace and mercy, the writer and the

team were given the opportunity to complete the Article Module for the implementation of

the manufacturing process practicum in the 2019/2020 educational year.

In this module the authors and team re-designed our masterpiece of practicum products

namely Stirling Engine, where we added 2 pistons and enlarged the scale of parts that were

made in the previous version for the needs of integrated practicum activities in the Faculty of

Industrial and System Engineering

Prosman Laboratory Adviser

Rino Andias Anugraha, ST., MM

NIP : 99750032

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MANUFACTURING PROCESS LABORATORY ASSITANTS 2019/2020

Aldyan Nurfaizi B. Tau

Alia Agistina

Anak Agung Sri Nandini

Anggit Pratama

Bagas Arganto P.

Bela Pitria Hakim

Damario Haznam

Farras Burhanuddin

Gitanjali Widayu Diatri

Mario Adiprana Muki

Nafisha Herma Hanifha

Pangestu Rizky Purnama

Satria Rahmadani Putra

Sri Yuzarnimar

Tri Maisyah Nugrah Samudro

Zakaria Gunada

Abdurrahman Rashif

Annastasya Septiani

Aquilla Yunma Imaristha

Arief Tri Hendrayanto

Corie Ariesta Arbay

Dhiya Shafa Azizah

Dimas Rayhandika

Elisa Intan Puspitasari

Gamaliel Situmeang

Indah Ekanurhayati

Irfanul Zuhdi Nufrinal

Kholiq Giffari

M. Fachri Husamuddin

M. Arash Arisiah

M. Raihan Arrafi

M. Sohibul Wafa

Nisri Husna Faadhilah

Rafi Pragiwaka Gani

Tirza Ayu Nursazabillah

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MANUFACTURING PROCESS

LABORATORY

Document

Number

MODULE 2.1 Form

Number

Valid 2019

Module Machining Process

Labwork NC Code Milling

Student Outcomes SO2. Able to apply mathematics, science and engineering

principles to solve complex engineering problems in

integrated systems (including human, material,

equipment, energy, and information)

Learning Outcomes LO14. Students are able to make a process plan for a given product

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A. Tools and Requirements

Tools & Software Requirements

1. Personal Computer

2. Swansoft CNC Simulator

1. Labwork of Module 2.1

2. Guideline of Module 2.1

3. Stationary

B. References

Autodesk. (2014). Fundamentals of CNC Machining. United States of America: Autodesk Inc. Black, J. T. (2008). De Garmo's Material and Processes in Manufacturing Tenth Edition. United States of America: John Wiley and Sons Inc. Groover, M. P. (2010). Fundamentals of Modern Manufacturing: Materials, Processes, and Systems Fourth Edition. United States of America: John Wiley and Sons Inc. Singh, R. (2006). Introduction to Basic Manufacturing Processes and Workshop Technology.

New Delhi: New Age.

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C. Labwork Steps

Flow Process Charts Process Description

1. Read the study case well. Because the

study case contained information that will

be carried out.

2. Pay attention to the specifications of each

process (facing dan profiling).

3. Create a new CNC program on Swansoft

CNC Simulator in accordance with the

tutorial on labwork.

4. Setting tools and zero point on Swansoft

CNC Simulator in accordance with the

tutorial on labwork.

5. Create NC Code for facing sub program

and input it on Swansoft CNC Simulator.

6. Create NC Code for profiling sub program

and input it on Swansoft CNC Simulator.

7. Create NC Code for main program and

input it on Swansoft CNC Simulator.

8. Simulate NC Code that has been created

on Swansoft CNC Simulator in accordance

with the tutorial on labwork.

START

Read the study

case

Pay attention to

the specifications

of each process

(facing and

profiling)

Create a new

CNC Program

Setting tools and

zero point

END

Create NC Code

for facing sub

program

Create NC Code

for profiling sub

program

Create NC Code

for main

program

Simulate NC

Code

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MODULE 2.1

MACHINING PROCESS: NC CODE MILLING

1.1 Students are able to understand about Milling Machining Process

1.2 Students are able to understand about NC Code Milling

1.3 Students are able to create NC Code Milling

2.1 Milling Process

2.2 Main Classification of Milling Processes

2.3 Types of Milling Machines

2.4 Types of Milling Cutters

2.5 Numerical Control

2.6 Structure Program of Milling Process

2.7 NC Code for Milling

1. OBJECTIVES

2. OUTLINES

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3.1 Milling Process

The milling process is one of the basic machinery processes where the

reduction of workpiece material is done by cutting tools that rotate on the

workpiece. Sometimes the workpiece remains stationary, and the cutter feeds

the workpiece. In nearly all cases, a multiple-tooth cutter is used so that the

material removal rate is high (Black, 2008).

In milling process, a rotating tool with multiple cutting edges is fed slowly

across the work material to generate a plane or straight surface. The direction of

the feed motion is perpendicular to the tool’s axis of rotation. The speed motion

is provided by the rotating milling cutter. A cutting tool has one or more sharp

cutting edges and is made of a material that is harder than the work material

(Groover, 2010).

Figure 2.1.1 Milling Process (Autodesk, 2014)

3.2 Main Classification of Milling Processes

Two main classifications of milling processes are peripheral milling and face

milling. Here are some differences between those two milling processes.

1. Peripheral Milling

In peripheral milling the surface is generated by teeth located on the

periphery of the cutter body. Both flat and formed surfaces can be produced

by these methods as follows.

a. Cutter axis is parallel to surface being machined.

3. BASIC THEORY

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b. Cutting is accomplished by the peripheral teeth of the milling cutter.

c. Mostly performed on a horizontal milling machine.

Figure 2.1.2 Types of Peripheral Milling (Singh, 2006)

2. Face Milling

In face milling, the generated surface is at right angles to the cutter axis. It

can be produced by these methods as follows.

a. Cutter axis is perpendicular to surface being milled.

b. Cutting is accomplished by both the flat face of the cutter and the

peripheral teeth of the milling cutter.

c. Mostly performed on a vertical milling machine (Black, 2008).

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Figure 2.1.3 Types of Face Milling (Groover, 2010)

3.3 Types of Milling Machines

There are types of milling machines based on the direction of cutter:

a. Up Milling (Conventional)

The direction of motion of the cutter teeth is opposite the feed

direction when the teeth cut into the workpiece. It is milling “against the

feed”.

Figure 2.1.1 Types of Up Milling (Singh, 2006)

b. Down Milling (Climb)

The direction of cutter motion is the same as the feed direction when

the teeth cut the workpiece. It is milling “with the feed”.

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Figure 2.1.2 Types of Down Milling (Singh, 2006)

3.4 Types of Milling Cutters

Milling cutters are cutting tools typically used in milling machines or machining

centres to perform milling operations (and occasionally in other machine tools).

They remove material by their movement within the machine (e.g., a ball nose mill)

or directly from the cutter’s shape (e.g., a form tool such as a hobbing cutter).

Milling cutters are made in a wide variety of shapes and sizes. Milling cutters

may be classified in various ways, such as purpose or use of the cutters (Woodruff

keyseat cutters, T-slot cutters, gear cutters, etc.); construction characteristics (solid

cutters, carbidetipped cutters, etc.); method of mounting (arbor type, shank type,

etc.); and relief of teeth. The latter has two categories: profile cutters which

produce flat, curved, or irregular surfaces, with the cutter teeth sharpened on the

land; and formed cutters which are sharpened on the face to retain true cross-

sectional form of the cutter.

Figure 2.1.3 Types of Milling Cutters (Singh, 2006)

Workpiece Workpiece Workpiece

Workpiece

Workpiece Workpiece

Workpiece

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3.5 Numerical Control

The first numerically controlled (NC) machine tool was developed in 1952 at the

Massachusetts Institute of Technology (MIT). Numerical control is used to control

the work part motions during cutting (Groover, 2010). It had three-axis positional

feedback control and is generally recognized as the first NC machine tool (X, Y, Z)

(Black, 2008).

Numerical Control is a form of programmable automation in which the

processing equipment (e.g., machine tool) is controlled by coded instructions using

numbers, letters and symbols as follows.

a. Numbers form a set of instructions (or NC program) designed for a

particular part.

b. Allows new programs on the same machining for different parts.

c. Most important function of an NC system is positioning (tool and/or work

piece).

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The advantageous of NC Milling over conventional milling one as follows.

a. Flexibility with accuracy, repeatability, reduce scrap, high production

rates, and good quality.

b. Reduce tooling costs.

c. Easy machine adjustments.

d. More operations per setup, less lead time, accommodate design change,

and reduced inventory.

e. Rapid programming and program recall, less paperwork.

f. Faster prototype production.

g. Less-skilled operator and multi-work possible.

Figure 2.1.4 Axis on the Milling Machine (Autodesk, 2014)

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3.6 Structure of Program Milling

1. Title of Program

OXXXXX

Example: O12345

2. Homing Tool

G28 X0. Y0.

3. Select Tool

TX M06

TX: Number Tool (X means tool number)

M06: Tool Change

4. Rapid Move to Start Point

G00 G54 X... Y...

The tool will move to the X-axis and Y-axis.

5. Spindle On

G90 S800 M03

M03: Spindle Clockwise

M04: Spindle Counterclockwise

6. Program

G43 H0X Z50.

G90 G01 X10. Y15. F500

7. Safety Movement

G00 G28 Z0.

Select the Z-axis safe.

8. Spindle Off

M05

9. Homing Tool

G28 X0. Y0.

10. End Program

M30: Program end, it also stops the spindle and turns off the coolant. The program

pointer will be reset to the first block.

M02: Program end but does not advance the program pointer to the next block.

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3.7 NC Code for Milling

a. Example of NC Code Milling

PT. Prosman will make parts with a milling process on CNC machines. The

following figure will help the NC-Code programmer to determine the cutting tool

movement so that it will form the part as desired. (in mm)

In this case you are asked to create NC Code to do a facing on a part with

known data as follows.

Depth of cut : 10 mm

Feed rate (F) : 100 mm/minute

R plane : 5 mm

Spindle Speed (S) : 3000 rpm

Tool diameter : 10 mm

Tool number : 1

Stepover : 100%

Material : Dural

Allowance : 1 mm

Zero point : G54 (X25. Y10. Z0.)

Figure 2.1.5 Example to Create NC Code Milling

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Therefore, these are the NC Code that fulfill that case:

O01234; Program Title

G28 X0. Y0.; Homing Tool

T1 M06; Selection Tool no. 1 (T1)

G00 G90 G41 G54 X0. Y0.; Rapid Move to Start Point and Tool

Compensation

S3000 M03; Spindle on

G43 H01 Z5. M08; Tool Height Offset and Coolant On

G91 G01 Z-5. F100; Program, Use Z-0.5 to Safety Point

from Workpiece

G91 GO1 Z-10.;

G91 G01 X120.; A to B and Start-Up Move

X50. Y50.; B to C

Y50.; C to D

G03 X-30. Y30. R30.; D to E

G01 X-120.; E to F

X-20. Y-20.; F to G

G01 Y-110.; G to A and Cancellation Move

G00 G40 Z0.; Safety Movement and Homing Tool


M09; Coolant Off

M05; Spindle Off

M30; End Program

Notes:

[1] Black font is used as the standard form of code structure

[2] Blue font is used as the movement of tool that follows the shape of the

geometry

[3] Red font is used as the tool movement in G code

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b. Create NC Code Milling for Operation

In this case you are asked to create NC Code to do a facing on a part with known

data as follows.

Depth of cut : 2 mm

Feed rate (F) : 100 mm/minute

R plane : 5 mm

Spindle Speed (S) : 800 rpm

Tool diameter : 20 mm

Tool number : 1

Stepover : 100%

Material : Dural

Allowance : 1 mm

Zero point : G55(X120. Y10. Z0)

Figure 2.1.6 Example to Create NC Code Milling

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• Facing Main Program



T1 M06; Selection Tool no. 1 (T1)

G00 G90 G55 X0. Y0.; Rapid Move to Start Point

S800 M03; Spindle on

G43 H01 Z10.; Tool Height Offset

G90 G01 Z10. F100;

M98 P22009 L3; Calling Subprogram and Loop

it 3 Times

G28 Z0.; Homing Tool

G28 X0. Y0.;

M05; Spindle Off

M30; End Program

• Facing Sub-Program


G90 G01 Z-2. F100; Feed movement to Z-2 and feed

rate 100

G91 G01 X-140.; Feed movement to right stock

with distance X-140

G00 Y20.; Fast transverse to Y20 without

feed movement

G01 X140.; Feed movement to left stock with

distance X140

G00 Y20.; Fast transverse to Y20 without

feed movement

M99; End of subprogram

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Black, J. T. (2008). De Garmo's Material and Processes in Manufacturing Tenth Edition.

United States of America: John Wiley and Sons Inc.

Groover, M. P. (2010). Fundamentals of Modern Manufacturing: Materials, Processes, and

Systems Fourth Edition. United States of America: John Wiley and Sons Inc.

Singh, R. (2006). Introduction to Basic Manufacturing Processes and Workshop

Technology. New Delhi: New Age.

4. REFERENCES

manufacturing process article · and input it on swansoft cnc simulator. 6. create nc code for...

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