manufacturing process article · telkom university. manufacturing process laboratory. (2018). modul...

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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

5

MANUFACTURING PROCESS

LABORATORY

Document

Number

MODULE 2.2 Form

Number

Valid 2019

Module Machining Process

Labwork NC Code Turning

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. HAAS Control Simulator 1. Labwork of Module 2.2

2. Guideline of Module 2.2

3. Stationary

B. References

Autodesk CAM . (2014). Fundamentals of CNC Machining. Autodesk CAM. (2014). Fundamentals of Machining. CNC Programming Basics, Tutorials, and Example Code. (2019, March 2019 19th). Retrieved from http://www.helmancnc.com/fanuc-g71-turning-cycle/ HAAS Automation Inc. (2015). Lathe Series Training Manual: HAAS CNC Lathe Programming. USA: Productivity inc. Manufacturing Process Laboratory. (2018). Manufacturing Process Training Module. Telkom University. Manufacturing Process Laboratory. (2018). Modul Pelatihan NC Code Milling dan Turning Novice 1.0. Bandung: Universitas Telkom. Manufacturing Process Laboratory. (2018). Modul Pelatihan Proses Manufaktur . Bandung: Universitas Telkom. Manufacturing Process Laboratory. (2018). NC Code Milling and Turning Training Module. Bandung: Telkom University.

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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 done

in the labwork.

2. Pay attention to detail case and instruction

specifications for each process.

3. Create NC Code and input it on to HAAS

Control Simulator.

4. Simulate NC Code that has been created on

HAAS Control Simulator according to the

tutorial on the labwork.

START

Read the study

case

Pay attention to

the

specifications

of each process

Create NC

Code

Simulate NC

Code

END

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MODULE 2.2

MACHINING PROCESS: NC CODE LATHE

1.1 Students are able to understand about Lathe/Turning Machining Processes.

1.2 Students are able to understand about NC Code Lathe.

1.3 Students are able to create and simulate NC Code of Lathe Processes.

1.4 Students are able to operate HAAS Control Simulator.

2.1 Overview CNC Turning.

2.2 Lathe Components.

2.3 Lathe Coordinate System.

2.4 2-Axis Lathe CNC Machine.

2.5 Tool Nose Compensation.

2.6 Part Datum.

2.7 Tools and Tool Holders.

2.8 Program Structure of NC Code Lathe.

2.9 Setup.

2.10 G71 O.D./I.D. Stock Removal.

2.11 G70 0.D./I.D. Finishing Cycle.

2.12 G75 O.D./I.D. Grooving Cycle.

2.13 G75 Cut Off.

2.14 G81 Drill Canned Cycle.

2.15 G83 Normal Peck Drilling Canned.

1. OBJECTIVES

2. OUTLINES

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3.1 Overview CNC Turning

CNC Turning is a manufacturing process in which bars of material are held in a

chuck and rotated while a tool is fed to the piece to remove material to create the

desired shape. A turret (shown center), with tooling attached is programmed to

move to the bar of raw material and remove material to create the programmed

result.

Figure 2.2.1 Turning Machine (Autodesk CAM, 2014)

There are many different configurations of CNC lathes. Some have two

spindles, some two tool turrets, and some even integrate milling or grinding in the

same machine. There is also variation between similar machines.

3.2 Lathe Components

Major components of a CNC Lathe.

Figure 2.2.2 Lathe Components (Autodesk CAM , 2014)

3. BASIC THEORY

1. Sheetmetal

2. Door

3. Spindle

4. Turret

5. Control

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1. Sheetmetal

Protective housing that contain cutting chips and capture coolant for recycling.

2. Door

Door is closed during operation. Lathes can be dangerous if the part is thrown

or a tool breaks during machining. The window is made from a special high impact

glass. The lathe should not be operated if this glass is cracked.

3. Spindle

Spindle is attached at one end the machine drive system. The other end

attaches the chuck, which grips the part.

Figure 2.2.3 Spindle Detail (Autodesk CAM , 2014)

4. Turret

Turret holds and moves the tools. Tools are bolted to the turret using a variety

of specialized holders, depending on the type of the tool. The turret indexes to

present the tool to the workpiece.

Figure 2.2.4 Turret Details (Autodesk CAM , 2014)

1. Spindle

2. Chuck

3. Jaws

4. Part

1. Tool Station

2. Tool Block

3. Face/Turn Tool

4. Face Groove Tool

5. Turret

6. Boring Bar Tool

7. Live Tool (Radial Mount)

8. Live Tool (Axial Mount)

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5. Control

CNC control used to operate the machine, includes functions to make

programming easier.

3.3 Lathe Coordinate System

Most lathes are 2D machines based on a Z-X Coordinate System. As shown in

figure 2.2.5, the Z-axis is parallel to the machine spindle and the X-axis is

perpendicular to the spindle. Normal spindle rotation is counterclockwise, though

direction can be reversed for left-handed threads just like with a mill by commanding

the proper G-code.

Figure 2.2.5 Lathe Coordinate System (Autodesk CAM , 2014)

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3.4 Axis Lathe CNC Machine

The definition of lathe is a machine that shapes objects by rotating them while a

shaping tool such as a chisel is applied to its surface or in other reference it called

turning process. A lathe is a machine tool which turn cylindrical material, touches a

cutting tool to it and cuts the material. The lathe is one of the machine tools most

well used by machining. A lathe machine can be used to create symmetrical shapes

into a piece of wood metal or other material.

Figure 2.2.6 Lathe Operations (Autodesk CAM , 2014)

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3.5 Tool Nose Compensation

The corners of lathe tools are radii. The imaginary tool tip is where vertical and

horizontal lines tangent to the cutting edge of the tool intersect. This point is found

by touching off the tool in the Z and X directions on the part or using a tool probe.

Because the imaginary tool tip can be found with great precision, it is used to control

the tool. That is, all the Z-X coordinates in the G-code program are in reference to

this point. Tool positions are easy to calculate parallel to the machine axes, but more

complex for arcs and chamfers.

Figure 2.2.7 Tool Nose Compensation (Autodesk CAM , 2014)

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3.6 Part Datum

The part datum is usually set as the center-face of the finished part.

Figure 2.2.8 Part Datum (Autodesk CAM , 2014)

Lathe tools have two tool offsets: Z and X, which is the distance from the

imaginary tool tip at home position to the part datum. There are two ways to set

lathe tool offsets. The first involves making a small cut (try cut) on the OD and face

of the stock material. The diameter is measured and entered in the control for the

X-axis offset. Subsequent tool offsets are found in reference to these faces.

Figure 2.2.9 Tool Offsets (Autodesk CAM , 2014)

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3.7 Tools and Tool Holders

While lathes use some of the same tools that mills use, including spot drills, drills,

and taps, most turning is done using carbide inserts. Inserts are gripped in holders,

which in turn are bolted to the lathe turret.

Figure 2.2.10 Typical Lathe Tool Holders (Autodesk CAM , 2014)

3.8 Program Structure of NC Code Lathe

The table below is the structure of NC Code Lathe:

Table 2.2 1 Program Structure of NC Code Lathe

No. Structure Explanation

1. Program Number Contains the number of the program that will be or have been made. Consists of 5 digits. Examples of writing is ‘O00111’.

2. Homing Tool Tool is located in machine home, where initial tool is located.

3. Tool Selection Choosing the appropriate tool with the machining process.

4. Setting Spindle Turning on the spindle, set the spindle speed and the spindle direction.

5. Rapid Move To Starting Point

Tool moves quickly to the point of initial coordinates that have been determined prior to machining or before feeding workpiece.

6. Machining Program (G70/G71/G81/G83)

Contains machining program that will be or have been made according to the shape of the workpiece to be made.

7. Content of Program Contains a machining program according with the shape of the workpiece shape or part. Consisting of [P] the starting block and [Q] ending block.

8. Homing Tool Tool back toward machine home, applying a rapid move.

9. Spindle Off Turning off the spindle.

10. Ending Process Ending of running program.

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3.9 Setup

The part is gripped in hard jaws, soft jaws, or collet. Part datum is usually the

center-face of the finished part. Provide enough excess stock to securely grip the

part. The back side of the part should be as close to the jaws as possible while

providing clearance for the cut off tool.

Figure 2.2.11 Setup

3.10 G71 O.D./I.D. Stock Removal

G71 Removal Stock is a program used for rough-material removal from

a CNC Lathe component. Cutting can be done in simple straight line or a

complex contour can also machine easily.

Machining Program:

D = Depth of cut for each pass of stock removal, positive radius.

F = Feed rate to use throughout G71 PQ block (the unit is in

mm/revolution).

I = X-Axis size and direction of G71 rough pass allowance, radius.

K = Z-Axis size and direction of G71 rough pass allowance.

P = Starting block number of path to rough.

Q = Ending block number of path to rough.

S = Spindle speed to use throughout G71 PQ block.

T = Tool and offset to use throughout G71 PQ block.

(G71 P……Q…...U…...W…...D…...F)

1. Jaw

2. Chuck

3. Stock

4. Extra Stock for

Grip/Cut Off

5. Part Datum

6. Extra Stock for

Facing

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U = X-Axis size and direction of G71 finish allowance, diameter.

W = Z-Axis size and direction of G71 finish allowance.

Programming Example G71 (O.D. Turning)

In this case, G71 using tool number 1, with spindle speed is 1000 rpm.

The finishing allowance of X-axis and Z-axis in G71 is 0.1 mm and 0.1 mm, and

the depth of cut is 0.2 mm and while the feed rate is 0.15 mm/rev with starting

point at X = 41 and Z = 2.

Figure 2.2.12 G71 O.D. Example

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

O01111 (O.D. Turning); Program Number

G28 U0; Homing Tool

G28 W0; Homing Tool

T101; Selection Tool No. 1 (T101)

G97 S1000 M03; Setting Spindle

G00 G54 Z2.; Rapid Move to Start Point

X41.;

G71 P1 Q2 U0.1 W0.1 D0.2 F0.15; Machining Program

N1 G00 X10.; Program Content

G01 Z-5.;

G03 X20. Z-10. R5.;

G01 Z-15.;

Z-20. X30.;

Z-25.;

G02 X40. Z-30. R5.;

G01 Z-32.;

N2 X41.;

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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.

Programming Example G71 (I.D. Turning)


The finishing allowance of X-axis and Z-axis in G71 is 0.1 mm and 0.1 mm,

and the depth of cut is 0.2 mm and while the feed rate is 0.15 mm/rev with

starting point at X=0 and Z=2.

Figure 2.2.13 G71 I.D. Example


O02222 (I.D. Turning); Program Number

G28 U0; Homing Tool

G28 W0; Homing Tool



G00 G54 X0. Z2.; Rapid Move to Start Point

X0.;


G28 U0; Homing Tool

G28 W0; Homing Tool

M05; Spindle Off

M30; End of Program

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G01 Z-5.;

X35. Z-10.;

Z-15.;

X23.;

G03 X13. Z-20. R5.;

G01 Z-23.;

N2 X0.;

G28 U0; Homing Tool

G28 W0; Homing Tool

M05; Spindle Off

M30; End of Program

Notes:



geometry.


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3.11 G70 O.D./I.D. Finishing Cycle

G70 finishing cycle is a phase consist of a pass along the programmed

tool path to remove excess material left by roughing phase, it makes the

workpiece smoother. G70 is used after the removal cycles such as G71, G72,

and G73. But it can also be used alone.

Machining Program:

P = Starting block number of routine to execute.

Q = Ending block number of routine to execute.

F = Feed rate (mm/rev).

Figure 2.2.14 G70 Finishing Cycle

(G70 P…...Q…...F…...)

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Programming Example (G70)

In this case, G70 using tool number 1, with 1200 rpm spindle speed,

while the feed rate is 0.15 mm/rev.

Figure 2.2.15 G70 Example


O03333 (Finishing Cycle); Program Number

G28 U0; Homing Tool

G28 W0; Homing Tool




X41.;



G01 Z-5.;

G03 X20. Z-10. R5.;

G01 Z-15.;

Z-20. X30.;

Z-25.;

G02 X40. Z-30. R5.;

G01 Z-32.;

N2 X41.; Program Number

S1200;

G70 P1 Q2 F0.1;

G28 U0; Homing Tool

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G28 W0; Homing Tool

M05; Spindle Off

M30; End of Program

Notes:



geometry.


3.12 G75 O.D./I.D. Grooving Cycle

G75 Grooving cycle is used for external or internal grooving.

Machining Program:

X = Axis absolute grooving depth, diameter value (mm).

Z = Axis absolute location to the furthest peck (mm).

I = X-Axis size of increment between pecks in a cycle (radius measure).

K = Z-Axis size of increment between peck cycles.


Figure 2.2.16 G75 Grooving Cycle (Autodesk CAM , 2014)

(G75 X…...Z…...I…...K…...F…...)

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Programming Example (G75 O.D.)

In this case, G75 O.D. using tool number 2 (tool diameter 2 mm), with

spindle speed is 800 rpm. The X-axis pecking depth is 0.2 mm and Z-axis

pecking depth is 1.5 mm and while the feed rate is 0.15 mm/rev with starting

point at X = 18 and Z = -20.

Figure 2.2.17 G75 O.D. Example


O04444 (OD Grooving); Program Number

G28 U0; Homing Tool

G28 W0; Homing Tool



G00 G54 Z-20.; Rapid Move to Start Point

X18.;

G75 X10. Z-12. I0.2 K1.5 F0.15; Program Content

G28 U0; Homing Tool

G28 W0; Homing Tool

M05; Spindle Off

M30; End of Program

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Notes:



geometry.


Programming Example (G75 I.D.)

In this case, G75 I.D. using tool number 3 (tool diameter 2 mm), with

spindle speed is 800 rpm. The X-axis pecking depth is 0.2 mm and the Z-axis

pecking depth is 1.5 mm and while the feed rate is 0.15 mm/rev with starting

point at X=0 and Z= 5.

Figure 2.2.18 G75 I.D. Example


O05555 (ID Grooving); Program Number

G28 U0; Homing Tool

G28 W0; Homing Tool




X0.;

G01 Z-20. F1.;

G75 X30. Z-12. I0.2 K1.5 F0.15; Program Content

G28 U0; Homing Tool

G28 W0; Homing Tool

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M05; Spindle Off

M30; End of Program Notes:



geometry.


3.13 G75 Cut Off

G75 Cut Off is used for smooth disposal of machining chips in transverse

cut-off machining. This allows easy disposal of machining chips in face turning

as well. Both G74 and G75 which are used for cutting off, grooving or drilling,

are cycling to give the escape of a tool automatically. Four patterns which are

symmetrical with each other are available. During single block operation, all

the blocks are executed step by step.

Machining Program:

X = Axis absolute grooving depth, diameter value (mm).

Z = Axis absolute location to the furthest peck (mm).

I = X-Axis size of increment between pecks in a cycle (radius measure).

K = Z-Axis size of increment between peck cycles.


Figure 2.2.19 G75 Cut Off (Autodesk CAM , 2014)

(G75 X…... I…...K…...F…...)

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Programming Example (G75 Cut Off)

In this case, G75 Cut Off using tool number 2 (tool diameter 2 mm), with

spindle speed is 500 rpm. The X-axis pecking depth is 0.2 mm and while the

feed rate is 0.08 mm/rev with starting point at X = 42 and Z= 2.

Figure 2.2.20 G75 Cut Off Example

Therefore. These are the NC Code that fulfill that case:

O06666 (OD Grooving); Program Number

G28 U0; Homing Tool

G28 W0;




X42.;

G01 Z-22. F1.;

G75 X0. I0.2 F0.08; Program Content

G28 U0; Homing Tool

G28 W0; Homing Tool

M05; Spindle Off

M30; End of Program

Notes:



geometry.

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3.14 G81 Drill Canned Cycle

G81 Drill Canned Cycle is the machining process to make prefix hole as

a mark so that the further process still on its axis.

Machining Program:

Z = Absolute Z-Depth (feeding to Z-Depth from R-Plane) (mm)

R = Rapid to R-Plane (where you rapid, to start feeding) (mm)

F = Feed rate (mm/rev)

Figure 2.2.21 G81 Drill Canned Cycle

3.15 G83 Normal Peck Drilling Canned

G83 Normal Peck Drilling Canned Cycle is a program to make a hole by

drilling with pecking.

Machining Program:

Z = Absolute Z-Depth (feeding to Z-Depth from R-Plane) (mm).

Q = Pecking Depth Amount, always incremental (if I, J, K are not used) (mm).

R = Rapid to R-Plane (where you rapid, to start feeding) (mm).


(G81 Z…...R…...F…...)

(G83 Z…...Q…...R…...F…...)

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Programming Example (G81 & G83)


The hole depth is 3 mm and rapid to R-Plane is 5 mm while the feed rate is 0.05

mm/rev with starting point at X = 0 and Z = 10.

G83 using tool number 5, with spindle speed is 500 rpm. The hole depth

is 15 mm and the amount of pecking depth is 2 mm and rapid to R-Plane is 5

mm while the feed rate is 0.05 mm/rev with starting point at X = 0 and Z = 10.

Figure 2.2.22 G81 and G83 Example

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O07777 (Drilling) ; Program Number

G28 U0; Homing Tool

G28 W0;




X0.;

G81 Z-3. R5. F0.05; Machining Program

G80 G01 Z10. F1.;

G28 U0; Homing Tool

G28 W0;

M05; Spindle Off




X0.;

G83 Z-15. Q2. R5. F0.05; Machining Program

G80 G01 Z10. F1.;

G28 U0; Homing Tool

G28 W0; Homing Tool

M05; Spindle Off

M30; End of Program

Notes:



geometry.


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Autodesk CAM . (2014). Fundamentals of CNC Machining.

CNC Programming Basics, Tutorials, and Example Code. (2019, March 2019 19th).

Retrieved from http://www.helmancnc.com/fanuc-g71-turning-cycle/

HAAS Automation Inc. (2015). Lathe Series Training Manual: HAAS CNC Lathe

Programming. USA: Productivity inc.

Manufacturing Process Laboratory. (2018). Manufacturing Process Training Module.

Telkom University.

Manufacturing Process Laboratory. (2018). NC Code Milling and Turning Training Module.

Bandung: Telkom University.

4. REFERENCES

manufacturing process article · telkom university. manufacturing process laboratory. (2018). modul...

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