CNC Milling
CNC Milling
CNC Milling
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, as shown in this view of a manual mill table. A
standard manual light-duty mill (such as a Bridgeport) is typically assumed to have four axes
as table x, table y, table z and milling head z.
A five-axis CNC milling machine has an extra axis in the form of a horizontal pivot
for the milling head, as shown below. This allows extra flexibility for machining with the end
mill at an angle with respect to the table. A six-axis CNC milling machine would have
another horizontal pivot for the milling head, this time perpendicular to the fifth axis. CNC
milling machines are traditionally programmed using a set of commands known as G-codes.
G-codes represent specific CNC functions in alphanumeric format.
HISTORY
The history of CNC milling dates back well into the 20th century, and it is interesting
to note that the very first CNC machines were actually almost as complex as the ones you
find today in modern CNC machine shops. The very first CNC technology came about just
after the Second World War, and it was initially used to manufacture parts for the aerospace
industry.
The precursor to the history of CNC milling was indeed numerically controlled
machines, and NC was developed by John Parsons. Working at his fathers factory, he first
developed rotor blade templates that would be used for helicopters. This very first attempt at
NC allowed data to be punched onto cards. Parsons would then go on to work on many
projects within the Air Force, and he started work with the MIT in 1949. It was here that the
first experimental CNC machine would be constructed.
Be sure that all machines have effective and properly working guards that are always
supervision.
Dont try to stop the machine with your hand or body.
Always see that work and cutting tools on any machine are clamped securely before
starting.
Keep the floor clean of metal chips or curls and waste pieces, put them in container
enough.
Always wear safety glasses or face shields designed for the type of the work operating
any machine
Always wear safety shoes inside and around the workshop.
Wear clothing suited for the job.
Dont wear neck ties or loose turn clothing of any kind.
Dont leave tools or work on the table of a machine even if the machine in not
turning. Tools or work may fall off and cause the fact of injury.
Put tools always when not in use.
PROCEDURE
9. Once the design is approved, cut stock to size. Follow all safety guidelines for this,
and if need help or instruction, ask the instructor or lab supervisor.
Tool
Stock Size
Contour
Face
Engrave
Drill
Swept
Ruled
Surface of Revolution
6. Specify the critical parameters of the cut. Most important is the "Z Final" amount,
which is the bottom of the cut. If the top of the work piece has a z coordinate of zero,
then all of the machining will be in the z-negative direction. The Step Size refers to
how much material is removed per pass, so in the illustration above, the cut would be
made in a single pass since .05" is less than .0625". Again, if the top of the stock is at
Z0, then Z Final will be negative.
7. When all of the parameters are correct, click OK to exit the Setup dialog box.
8. Select the geometry. (This could have been done prior to clicking Setup.) Use the
Shift key to select multiple geometries. Selected geometries show up as dashed lines.
9. Click the "Go!" button. If the red lines indicating the centerlines of tool paths look
correct, then accept the tool paths.
10. Re-set the parameters for each machining operation. After adding additional tool
paths, and deleting erroneous ones, export the numerical control code by clicking the
NC button.
1. At a computer controlling a mill, turn on the mill's power supply now so that
the control program does not start in simulation mode.
2. Fill out the machine log for this mill.
3. At the Benchman controlling computer, open Benchman MX, and click
through any error messages. Then at the computer controlling the ProLight
1000 or at any computer not connected to a milling machine, open CNC Base
for the ProLight 1000 Machining Center program. This is essentially identical
to the Benchman control software, and it is used on computers not connected
to the Benchman for verification, even if you later will do the machining on
the Benchman.
4. Open your NC file within that program.
5. If the NC code screen has a grey background, click Edit, Lock, to unlock it
and allow editing. Rearrange the windows as needed.
6.
Click Tools, Select Tool, and select the appropriate tool. If it is not available, add it to
the library and then select it.
7.
Click the red Verify button. Click Verify Options and then make sure that the stock
size, origin, and initial tool position are correct.
8.
Fix the program as necessary. Typically, the program will leave the tool embedded in
the stock. If it does, add additional lines to extract the tool and send it back to its
starting position. Make other changes as needed, but with each of them, be sure to
verify the program after making changes, and then to save the verified version.
Syntax
and
Example
G0[destination]
G0X0Y0-Z.1
G1
G2
G1[destination]
G1Z-.1
G2X2Y1.5I1.5J1.5
Alternatively:
G2[endpoint xyz][radius]
G2X1Y1.5R.5
G3
point. Please make sure the starting point (which is not in the
syntax but is where the tool is after the previous line) and the
endpoint are equidistant from the center point.
G3X2Y1.5I1.5J1.5
not in the syntax but is where the tool is after the previous
line) and the endpoint are equidistant from the center
point or you will get a bad points error.
G4F[seconds]
G4F3
G5
G5
G90 G90
G91 G91
M1
M1
M2
M2
M3
M3S[rpm]
M3S2000
M5
M5
M6
M6T3 (Neither the Benchman Tool Change. Switches to the specified tool in the turret.
nor PLM 1000 is equipped Please make sure that you first move to a safe place, because
with a tool change feature. Do as the turret turns, some other tool might be sticking out too
N1
F3
S
S2000
M6T1 (Neither the Benchman Tool Designation. Used after a Tool Change command, T
nor PLM 1000 is equipped identifies the number of the tool to insert.
with a tool change feature. Do
not use this.)
G2[orG3][endpoint xyz]
[radius]
G3X2Y1.5R.5
;
;[remark]
N1; Part Name: GearHousing1 semicolon are ignored by the NC machine, allowing the
author to add comments and annotations.
Safety glasses are required in AT 141. Turn on the Benchman MX milling machine,
so put them on and ask those around to do the same. If have not yet done so, turn on
Benchman power with the Green ON button; if using the Prolight 1000 Milling
Machine, be sure to turn on its power supply /
controller box.
2.
in.
3.
4.
5.
6.
7.
Select Tools, Select Tool, and then select the correct tool for this job. If it is not there,
you might need to add it to the list and then select it.
2.
above it.
b. Open the door to
c. Use a piece of
move
the
tool
the Benchman.
paper as a feeler gage, and
down .001" at a time until it
just touches the paper. The paper should still slide, but with some resistance.
d. If don't see a readout of the X, Y, and Z coordinates, click View, Position.
Then right click on that position readout (and on earlier versions on the
Machine Info window pictured below) and select Set Position.
e.
Enter the position of the tool along the Z axis. If the top of your stock is at Z0,
and the paper is .004" thick, you would enter a positive .004 as the Z position.
All of your machining would be in the Z negative range.
f.
2.
3.
4.
Move the tool to the starting position. Do this by right clicking on the Machine Info
window and then clicking Go To. Type in the coordinates of the starting position and
double check these. If flip any positions, make a mistake with plusses and minuses, or
leave out a decimal place, the tool could crash into the vise and break. When sure the
coordinates are accurate and the path to them is clear, click Go Rapid.
Verify the code one more time and save the verified
version.
2.
3.
Check again to make sure the tool is held securely, the stock is held securely, and both
the spindle wrench and the spindle lock cylinder have been removed.
4.
Make sure the door is closed and latched, the emergency stop is disengaged, and the
override control dials are near their center positions.
5.
Make sure the readout of the coordinates on the screen matches where the tool is.
6.
Make sure that you and everyone around is wearing safety glasses.
7.
Get the lab supervisors approval to machine before you run the program for your first
time.
If received the lab supervisor's permission and you are confident in work, then click
on the green Run button. There may be two built-in delays that require keyboard
action, so take that action.
2.
While the part is machining, stay with it and monitor it; your hand should be on the
Red Emergency Stop button for the first time you run the part. If anything goes
wrong, like the stock coming out of the vise or the tool heading in the wrong
direction, press the emergency stop button. There are two additional emergency stop
icons on the software that function in the same way.
3.
When the milling machine has come to a complete stop at the very end of the
program, press in the Red Emergency Stop button, lift the cover, and remove your
part.
4.
Repeat the milling procedure as needed for additional parts and re-establish
coordinates for each piece.
When you are done for the day, please clean the mill. Vacuum out the debris. Put all
tools and materials away. Power-down the computer and the mill.
2.
3.
As needed, post-process your product. If there are any problems, report these to the
lab administrator right away.
ADVANTAGES
DISADVANTAGES
Provide a high degree of quality because of Costs quite a lot more than conventional
their accuracy and their ability to reuse machinery
programs.
Once the first piece has passed inspection, Costs quite a lot more than conventional
minimal
inspection
is
required
on machinery
subsequent parts
Advanced
machine
control
their
purchase
requires
extensive
normally
conventional machines
CONCLUSION
require
several
REFERENCE
http://jcflowers1.iweb.bsu.edu/rlo/cadcammilling.htm
https://www.scribd.com/doc/114722893/cnc-milling-report
https://www.dlsweb.rmit.edu.au/toolbox/furnishindustry/toolbox/shared/resources_m
w/ask_expert/tony/advantages.htm
https://www.scribd.com/doc/152443952/Tugasan-Mekanikal-Report-Bengkel-CNCEDM-DIE-SINKING