ESSAR ACADEMY FOR STEEL

Study of available machining process

Essar heavy engineering service

Prepared by: 1. Nitish Kumar 2.RamGopal 3.Shyam Sunder 4.Satyandra Singh Rathore

Project Guided by: Mr. Rajiv Mistry

Study of available machining process

Objectives: Introduction of EHES Available machines into MACHINE SHOP Specification of machines CNC lathe machine

Parts of CNC machines Types of machining process on CNC LATHE Basic fundamental of CNC lathe machine CNC programming on CNC lathe Example of CNC lathe programming

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Study of available machining process

INTRODUCTION

TO EHES-

ESSAR HEAVY ENGINEERING SERVICES IS A MANUFACTURING FACILITY OF ESSAR CONSTRUCTION (INDIA) LTD. AND A KEY BUSSINESS VERTICAL OF ESSAR PROJECTS LTD ,AN ESSAR GROUP COMPANY.

PRODUCTS : Pressure vessels & heat exchangers towers & reactors Steel plant equipment and machinery Material handling equipment Available facilities in ehes Fabrication facilities

Machining facilities Inspection facilities Mechanical and chemical testing facilities

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Study of available machining process

Available

machines into MACHINE SHOP -

List of machines SPECIFICATION OF MACHINES

A A A A A A A A A

CNC LATHE MACHINE Parts of cnc machine Machine structure Slide ways Spindle mounting Drive units Elements of transmission and positioning slides Location of transducers Tool and work holding devices Swarf removal Safety
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MACHINE STRUCTURE The basic design of conventional machine tool is not suitable for CNC machines. Many design changes are required for CNC m/c as compared to the conventional machines The design and construction of CNC machine should be such that it meets the following main objectives High precision and repeatability Reliability Efficiency

To meet the requirement of high precision, repeatability, and high efficient the numerically controlled machine tools should have a structure that is correctly design to withstand normal weight distribution.

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The higher cuting speeds and feeds in cnc machines result in rapid acceleration and deceleration of the slides and machines are subjected to fluctuaing and variable forces during the machines operations. The machines parts should not be bend due to these all heavy load.

All the parts of m\c structure should remain in relative relationship regardless of the magnitude and direction of the stresses developed due to these forces. Slideways

In CNC machines the requirement of the movement in fluctuating motions are much needed because of highly machines utilization and movements.

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So the slide ways are also designed accordingly. Hydro static slideways Linear bearing with balls and rollers Surface coating

pumped into small pockets or cavities machined into the carriage which are in contact with slideway. The pressure of the fluid gradually reduces to atmosphere pressure as it sweeps out from the pockets through the gap between the slide and slideways. The hydrostatic slideway provides almost a frictionless condition for the movement of the slide. For efficient We have hydro static slideways. In this oil is operation it is required to have fluid and slideways clean.

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Spindle-

At high cutting speeds and high material removal rates it is required not to bend spindle due to external thrust and deflection forces. To ensure stability and minimise torsional strain the machine spindle is designed to be short and stiff and the final drive to the spindle is located as near to the front bearing as possible. The rotational accuracy of the spindle is dependent on the quality and design of bearing used.( ball andd roller bearings are mostly used) Drive units Drive motors are required to perform following functions spindle drive Axis drive Spindle driveEssar academy for steel
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The fluctuating cutting speed is provided by rotation of main spindle with the help of electric motor through gear mechanism. a- electrical motor b- fluid motor Ac.Electrical motor is used to drive the spindle . The drive may be directed from the motor to the machine spindle through belt and gear mechanism. Toothed belts are used to perform better. ac motor are most reliable easily maintenance and less cost. Speed variation caneasily take place into these motors by changing poles. The speed is changed by variation in frequency of the ac

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current with the help of frequency converters. (2) Axis driveThe CNC machine is controlled by servomotors. Because to differ axis working accomplishment accurate control of position and velocity stepper motors are used for axis drive. How steeper motor works? If a pulse is received from control system the motor spindle will rotate one step. The control unit generates the pulses according to the programmed value of movement required of the tool or work. The distance travelled by the carriage is calculated by the known value of the axis ball screw and by counting the number of pulses. Element of motion transmission-

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In cnc machines problem of accuracy and friction is overcome by using recirculating ball screw and nut. The connection between screw and the nut is through an endless steram of recirculating steel balls. these balls rotate between the screw and the nut and at some point the balls are returned to start of the thread inn the nut. Location of transducer All the m\c functions are transferred to a computerised control system. The facilities which a control unit should offer are(1) indicate the current status and position of various machine tool features and give feedback. (2) allow manual and semi manual control of machine tool elements

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(3) enable machine tool to be programmed

Two types of transducers should be positoned-near the sliding surface and lead screw - in an accessible position for maintenance purposes rotary transducers should be located - at the driving end of leadscrew - at free end of lead screw Tool and work holding devices-

Because the cnc machines can perform a number of jobs in a single setting so the tool and work hoding devices should also be as much durable. The holding device should bear multidirectional
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cutting forces. Hydraulics , pneumatic actuation is widely used in work holding devices. Swarf removal Unless the swarf is quickly and efficiently removed from the cutting zone it can affect the cutting process and the machine tool because it may hamper the access to the m\c tool. To avoid these problems swarf removal system is provided with the cnc machine tools with some mechanism to remove the swarf from the cutter and cutting zone and for the disposal of swarf from the machine tool area itself. Slant beds and vertical beds turning centers have the advantages over flat bed or horizontal bed configuration . Safety Protection of machine guideways, drivescrews, and transducers.
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Drives screws should be protected by using telescopic covers. Jets of cutting fluid should be used to wash away and clear the tool work area.

TYPES OF MACHINING PROCESS ON CNC LATHE

Turning

operations performed on a lathe include:

Straight turning Taper turning

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Study of available machining process

End facing Shoulder facing Facing Grooving

Turning

operations performed on a lathe include:

Grooving Form turning Parting-off Threading Knurling

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Study of available machining process

Drilling Reaming

CNC fundamentals
What is a CNC Machine?

CNC : Computer and Numeric Control Conventionally, an operator decides

and adjusts various machines parameters like feed , depth of cut etc depending on type of job , and controls the slide movements by hand. In a CNC Machine functions and slide movements are controlled by motors using computer programs.
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For a CNC machine control unit (MCU) decides cutting . speed, feed, depth of cut, tool selection , coolant on off . and tool paths. The MCU issues commands in form of. numeric data to motors that position slides and tool . accordingly.

Overview By integrating a computer processor, computer numerical control, or CNC as it is now known, allows part machining programs to be edited and stored in the computer memory as well as permitting diagnostics and quality control functions during the actual machining. All CNC machining begins with a part program, which is a sequential

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instructions or coded commands that direct the specific machine functions. The part program may be manually generated or, more commonly, generated by computer aided part programming systems.

Basic CNC Principles

All computer controlled machines are able to accurately and repeatedly control motion in various directions. Each of these directions of motion is called an axis. Depending on the machine type there are commonly two to five axes. Additionally, a CNC axis may be either a linear axis in which movement is in a straight line, or a rotary axis with motion following a circular path.

Motion control - the heart of CNC The most basic function of any CNC machine is automatic, precise, and consistent motion control.

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Rather than applying completely mechanical devices to cause motion as is required on most conventional machine tools, CNC machines allow motion control in a revolutionary manner. All forms of CNC equipment have two or more directions of motion, called axes. These axes can be precisely and automatically positioned along their lengths of travel.

The two most common axis types are linear (driven along a straight path) and rotary (driven along a circular path). How CNC Works Controlled by G and M codes. These are number values and coordinates.

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Each number or code is assigned to a particular operation. Typed in manually to CAD by machine operators. G&M codes are automatically generated by the computer software. Features of CNC Machinery The tool or material moves. Tools can operate in 1-5 axes. Larger machines have a machine control unit (MCU) which manages operations. Movement is controlled by a motors (actuators). Feedback is provided by sensors (transducers) Tool magazines are used to change tools automatically. Tools Most are made from high speed steel (HSS),

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tungsten carbide or ceramics. Tools are designed to direct waste away from the material. Some tools need coolant such as oil to protect the tool and work. Tool Paths, Cutting and Plotting Motions Tool paths describes the route the cutting tool takes. Motion can be described as point to point, straight cutting or contouring. Speeds are the rate at which the tool operates e.g. rpm. Feeds are the rate at which the cutting tool and work piece move in relation to each other. Feeds and speeds are determined by cutting depth, material and quality of finish needed. e.g.

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harder materials need slower feeds and speeds. Rouging cuts remove larger amounts of material than finishing cuts. Rapid traversing allows the tool or work piece to move rapidly when no machining is taking place.

CNC Programming Basics Each letter address relates to a specific machine function. G and M letter addresses are two of the most common. A G letter specifies certain machine preparations such as inch or metric modes, or absolutes versus incremental modes. A M letter specifies miscellaneous machine functions and work like on/off switches for coolant flow, tool changing,
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or spindle rotation. Other letter addresses are used to direct a wide variety of other machine commands. CNC programming Important things to know:

Coordinate System Units, incremental or absolute

positioning

Coordinates: X,Y,Z, RX,RY,RZ Feed rate and spindle speed Coolant Control: On/Off, Flood, Mist Tool Control: Tool and tool parameters

CNC programming
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Study of available machining process

Programming consists of a series of instructions in form of letter codes

Preparatory Codes: G codes- Initial machining setup and establishing operating conditions

N codes- specify program line number to executed by the MCU Axis Codes: X,Y,Z - Used to specify motion of the slide along X, Y, Z direction Feed and Speed Codes: F and S- Specify feed and spindle speed Tool codes: T specify tool number Miscellaneous codes M codes For coolant control and other activities
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Programming Key Letters O - Program number (Used for program identification) N - Sequence number (Used for line identification) G - Preparatory function X - X axis designation Y - Y axis designation Z - Z axis designation R - Radius designation F Feed rate designation S - Spindle speed designation H - Tool length offset designation D - Tool radius offset designation T - Tool Designation M - Miscellaneous function

Explanation of commonly used G codes G00 Preparatory code to control final position of the tool and not concerned
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with the path that is followed in arriving at the final destination.

G01 Tool is required to move in a

straight line connecting current position and final position. Used for tool movement without any machiningpoint to point control. (linear interpolation)

G02 Tool path followed is along an arc

specified by I, J and K codes.( circular interpolation)

Table

of Important G codes

G00 Rapid Transverse G01 Linear Interpolation G02 Circular Interpolation, CW G03 Circular Interpolation, CCW G17 XY Plane,G18 XZ Plane,G19 YZ Plane G20/G70 Inch units
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G21/G71 Metric Units G81 Drilling cycle G82 Counter boring cycle G83 Deep hole drilling cycle G90 Absolute positioning G91 Incremental positioning

Table of Important M codes M00 Program stop M01 Optional program stop

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M02 Program end M03 Spindle on clockwise M04 Spindle on counterclockwise M05 Spindle stop M06 Tool change M08 Coolant on M09 Coolant off M10 Clamps on M11 Clamps off M30 Program stop, reset to start

Example of cnc programming We have a bar of 20 mm dia and we are doing following operations1. Facing 2. Turning `3. Taper turning

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We will do the programming by two methods1- absolute method 2- incremental method

Absolute Method N0010 G71 G90 G94 EOB N0020 T01 S1000 M03 EOB N0030 G00 X22 Z0.5 EOB N0040 G01 X0.00 F200 EOB N0050 Z0.00 EOB N0060 X20.00 EOB N0070 X15.00 EOB N0080 Z-15.00 EOB N0090 X20.00 Z-20.00 EOB N0100 Z-35.00 EOB N0110 G00 X25.00 Z20.00 EOB N0120 M02 EOB Incremental method N0010 G71 G91 G94 EOB N0020 T01 S1000 M03 EOB

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N0030 G00 X11.00 Z-0.5 EOB N0040 G01 X-11.00 F200 EOB N0050 Z-0.5 EOB N0060 Z11.00 EOB N0070 X-3.5 EOB N0080 Z-15.00 EOB N0090 X2.5 Z-5.00 EOB N0100 Z-15.00 EOB N0110 G00 X2.5 Z55.00 EOB N0120 M02 EOB

30 15mm
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15 5mm 15mm
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References Cnc machines book by m. adithan , b.s pabla Net sources Datas given by EHES and guided by Mr. Mitesh Ghayal sir Guided by Mr. Rajiv mistry sir Future planning Collect more information about other machines in EHES.

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THANKS

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