manufacturing process article · and input it on swansoft cnc simulator. 6. create nc code for...
TRANSCRIPT
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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
G28 X0. Y0.; 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
O11009; Program Title
G28 X0. Y0.; Homing Tool
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
O22009; Program Title
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