Final-CNC Lathe Machine Operational AND Programming Manual PDF

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CNC Lathe training manual for part programming, machine operation and machining on GSK,Fanuc, Siemen controllers....

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Cnc operational and programming guide

COMPUTER NUMERICAL CONTROL Century Star Turning CNC System PREFACE Understanding the broad range of CNC techniques and its application to actual subtractive machining promotes high productivity, competitive advantage and quality assurance in a manufacturing sector. As one of Big4Agenda, Offering CNC training will not only impart skills to machine operators but will create competent and self-sustaining operators. Prior to actual training, operators should understand basic and general machining areas such as: 

Understanding orthographic drawings.

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Workshop safety and protective gears.

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Measuring devices for subtractive machining.

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Machining operations for both lathe and milling.

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Cutting tools.

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For production managers: Understand shop orders and schedules.

Table of Contents TRAINING ........................................................................................................................... 1 LEARNING OBJECTIVES .................................................. Error! Bookmark not defined. APPLICABILITY ................................................................................................................. 2 PROCEDURE FOR PRACTICAL TRAINING .................................................................... 2 OBJECTIVES ................................................................................................................... 2 TOOLS, MACHINES AND MATERIAL REQUIRED ......................................................... 2 PROCEDURE OF PART PROGRAMMING ...................................................................... 19 Overview ........................................................................... Error! Bookmark not defined. TEST ASPECTS ................................................................................................................... 4 AIM FOR TODAY MACHINING: ....................................................................................... 4 Organization of documentation ............................................. Error! Bookmark not defined.

TRAINING For SolidCAM in depth training contact us through: Phone: +254702801545 or +254713660902 Email: [email protected] Website: www.dalkrinstechnologies.co.ke

WORKSHOP SAFETY A safe workshop is an integral facility for enhancing quality and relevance of technical skills in universities, promoting career choices for individuals and national developments. The challenge of technical training today is to offer experience that provide students with the opportunities to develop their understanding, skills and attitude and capacity identification thus helping universities to solve problems and tackle any changes that may befall them during their career progression. In workshops today, operators are aiming at providing products to the end users but little awareness is focused on the safety for the machine and the operations. The guide therefore presents a comprehensive approach to operational of the CNC machine, its safety and programming as a package to all users of the workshop. Although there still challenges of equipping the workshop to its required standard, we cannot ignore safety of the workshop personnel’s. The handbook is meant to offer effective and efficient inspection of the operational 1|Dalkrins Te ch nol og ie s CNC Tutori al f or beg inne rs

procedures that are aimed at equipping the users with sufficient skills in handling operation of the machines and safety procedures. The handbook is an addition to and not as a substitute for general safety principles applicable to all types of workshop in training institutions and industry. I hope these guidelines will help promote cohesive and conducive working environment for all users in terms of practical safety skills and operation of the machine according to the manufacture’s manual. APPLICABILITY     

This Programming Guide is applicable to the following CNC system: HNC-18iM/19iM v4.0 HNC-18xp/M HNC-19xp/M HNC-21MD/22MD v05.62.07.10

PROCEDURE FOR PRACTICAL TRAINING OBJECTIVES  To ensure coursework for workshop practice is well accomplished according to academic set objective through practical demonstration.  To produce hands-on and technically practical graduates.  To foster student’s innovation and realization through machining.  To expose graduates to challenges of real world though knowledge transfer and industry linkage.  To promote revenue generation for the university through machine hiring. TOOLS, MACHINES AND MATERIAL REQUIRED       

Turning training tools: -grooving tool, boring tool, drilling tool, threading tool, tapping tool, knurling tool and reaming tools. Measuring tools-vernier calliper, vernier HT gauge, thread gauge, dead gauge, dial gauge & centres. CNC lathe machine. Ban saw material Cutter. Sand paper. Filing sets. Packings.

SIMPLE PART PROGRAMMING PROCEDURE. 1.) Introduction to machine centres: ORIENTATION 

Orientation is done to first entry students on course work practice or IBL.

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      

Layout of CNC Lathe machines-location Advanced CNC workshop. Type of tools for Lathe operations. Preparation of Billet/Workpiece for Machining. Types of Manufacturing Technologies. Students must have knowledge about different types of Manufacturing-process of converting raw materials into finished product. Preparation of workshop practical report.

DAILY MACHINE CHECK-UP

Activities

PERIODIC MAINTENANCE PLAN Daily Weekly Monthly

Quarterly

Check lubricating level before start machining Check level of coolant before start machining Check for coolant pump pressure, if too low, clean and repair pump. Check and drain all compressors for any water accumulations, in the tank Cleaning machine table and sliders, after operations Machine Dusting (on Saturday afternoon) Pneumatic system check-up and repair MCU troubleshooting Check for circuit breakers damager and repair Machine overhaul repair and maintenance for critical parts Check for GA T 3/8F, Pneumatic tubes for replacement Workshop Cleaning Filters REQUIREMENTS FOR IBL TRAINING      

Safety boots. Dustcoats or overalls. Transparent goggles (1 pair). Cotton gloves (2 pairs). Log Book for entering daily tasks accomplished. Insurance cover for trainee.

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Yearl y

TEST ASPECTS The parts produced must contain all operations of turning such as:       

Step turning-used for mechanical elemental alignments in cases of gear box, pumps and differential. Taper turning-used in most case where tool holders are produced, internal shafts assemblies and other elements which are tapered by functionality. Drilling-to create a new hole for enlargement through reaming, tapping and boring in case of internal passages of components. Boring –enlargement of already drilled hole either by reaming or boring tool. Threading-both internal & external-used in case of shafts alignment and coupling. Knurling-to provide grip during assembly and fastening. Grooving-to create a seal slot for O-ring hence prevent leakage during machines operation.

AIM FOR TODAY MACHINING: 

To Test Effect of Two Stud Thread, Three Stud Thread & Four Stud Thread During Shaft Alignment

Contents to be covered during practical Training at Advanced mechanical Workshops      

Manual part programming and operation. Machine maintenance in both workshops Product design-Geometric modelling-CAD (Solidworks or Inventor) CNC and CAM- (SolidCAM or InventorCAM) Production Technology-Subtractive machining, Additive Manufacturing and Reverse Engineering. Product fabrication

NOTE: 

Strength of Machine Elements-To Test Torsion, Tension, Compression and Hardness

After Machining Has Been Done, Parts Produced Must Be Taken to Metrology Lab.     

Why Metrology Lab: Quality assurance To Measure Surface Roughness Surface Finish Tolerance Dimensional Accuracy

NOTES TO TRAINEES:   

At end of Training period, trainee must present a report that summarizes all activities done and any recommendations if need be. Workshop rules and regulations must be followed at all times-for more details check at OSHA workshop safety rules and regulations. Observe time.

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  

Training is only done on week days unless otherwise stated. Training starts from 10 am- 3.30 PM. Ensure all equipment and machines are cleaned after every use.

CHAPTER ONE: OPERATIONAL GUIDE

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Typical CNC –Lathe Machine

Operational Steps 1. Putting power on Lathe is switched on using power button shown below by arrow and given some time to startup.

2. Referencing the machine This is homing the machine and should be done each time the machine is powered on. It is done by pressing buttons shown below i.e., press home key on the MCP then press +X and +Z.

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Ref point

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3. Putting the workpiece in the chuck The work to be machined should be tightened coaxially in the chuck jaws.

workpiece

4. Putting the tool in the tool turret Tool turret carries a maximum of four tools, each tool in its position.

The tool number in the G-code should correspond with number on the tool turret i.e., T0202 in G-code means tool is in tool number two in the tool turret. Proper tool orientation should be considered i.e., Turning, External threading, grooving and parting off tools should be put along X-axis i.e., perpendicular to the workpiece while boring, internal threading and internal grooving tools should be put along Z-axis i.e., parallel to the workpiece.

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5. Tool and workpiece compensation This involves setting zero position of tool and workpiece before proceeding with machining operations. 

X-axis –done by touching the outer diameter of the workpiece and making a small cut



Z-axis-done by touching the end face using the tool so as to get workpiece zero

position

6. Actual machining This is actual starting of the G-code after doing all initial setting of lathe.

CHAPTER TWO: MAINTENANCE KEY AREAS

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1. Checking the level of lubricating oil.

Level of lubricating oil should not go below low level(L). When level go below low-level L, machine gives a NO LUBRICATION warning as shown below

2. Checking nature of coolant and amount Coolant should be whitish in color (as shown below) and should be in large amount.

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3. Cleaning machine after operation Metal chips shown below should be removed after machining for lathe cleanliness.

These chips may cause machine failure and rusting if left to accumulate for a long period of time. Chips are supposed to be removed every time the machine is used.

4. Cleaning chuck jaws Jaws are supposed to be cleaned once in a while so as to remove chips to avoid locking of

jaws

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Safety Measures When Operating Cnc Lathe 1. When not preforming any machining always ensure emergency button is on

2. Always close the door when machining

3. Ensure bulb is on when operating and machining

4. Do not change tool when n tool turret is near the workpiece or chuck. 5. NEVER rotate spindle Anticlockwise i.e. never use M04 6. Never leave workpiece on the chuck untightened 12 | D a l k r i n s T e c h n o l o g i e s C N C T u t o r i a l f o r b e g i n n e r s

7. Ensure emergency button is on when removing workpiece from the chuck 8. Never touch the part being machined or do anything else during machining 9. After using the machine always ensure it is homed and emergency button pressed CHAPTER THREE: CNC MILLING MACHINE OPERATION MANUAL

Typical CNC –Milling machine

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OPERATIONAL SEQUENCE OF MILLING MACHINE 1. Putting power on Milling machine is switched on using power button shown below by arrow and given some

time to start.

2.Putting the compressor on The compressor should be put on after putting the machine on. The compressor is turned on by flipping the knob (shown by the arrow) downwards. After switching on the compressor, you should allow the pressure of the machine to rise to a range between 11-13 bars.

3. Referencing the machine This is homing the machine and should be done each time the machine is powered on. It is done by pressing buttons shown below i.e., press home key on the MCP then press +Z and give it time to indicate zero then press +X and +Y.

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4. Putting the workpiece in Milling jig and clamping the jig on the table The work to be machined should be tightened in the milling fixture which then gets bolted on the table. There should be NO movement of the fixture and work piece.

5. putting the milling tool in the tool holder You should put one tool at a time on the tool holder or when dealing with several tools, the CNC machine has a tool magazine where you put your tools and the machine automatically interchanges them after operating on one tool.

6. Tool and workpiece compensation This involves setting zero position of tool and workpiece before proceeding with machining operations. 

X-axis and Y-axis zero point –it is determined by touching the outer diameters of the workpiece and making a small cut using the figures obtained to determine center of the workpiece. Values calculated are usually filled in G54-column.

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

Z-axis zero point-done by touching the end face using the tool so as to get workpiece zero position which is used by G43

6. Actual machining This is actual starting of the G-code after performing all initial setting of the CNC Milling Machine.

CHAPTER FOUR: MAINTENANCE KEY AREAS FOR MILLING MACHINE

1. Checking the level of lubricating oil.

You should not let the level of lubricating oil to go below the low level abbreviated as(L). When lubricant level goes below low-level L, machine gives a warning of NO LUBRICATION as shown below

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2. Checking nature of coolant and amount Coolant is a whitish liquid (as shown below) and should always be in large amounts.

3. Cleaning machine after operation Metal chips should be removed after operations for CNC Milling Machine cleanliness.

The metal fillings can cause rusting and machine failure if left to accumulate for a long period of time. Chips are supposed to be cleaned after every use of the machine.

4. Cleaning table and fixture The table and fixture are supposed to be cleaned after using the machine to avoid failure of the machine. They should be as shown below.

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Safety Measures When Operating Cnc Milling Machine 1. Always ensure emergency button is on when the machine is not in operation.

2. Always close the door of the machine when machining.

4. Do not touch the tool during machining. 5. NEVER rotate spindle Anticlockwise i.e., never use M04. 7. Ensure emergency button is on when removing workpiece from the fixture.

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9. After using the machine always ensure it is homed and emergency button pressed.

CHAPTER FIVE: PROCEDURE OF PART PROGRAMMING FOR LATHE MACHINE Introduction 2.) Introduction to machine centres:  Orientation is done to first entry students on course work practice or IBL.  Students are introduced on various mechanical components that require cleaning and repair, such parts are chuck jaws, spindle bearings, tool post, lubricant status, coolant container and piping system and lighting.  A review of manufacturing operations is emphasized apart from material removal processes. Other manufacturing process are vital towards realization of the entire prototype and / or projects for students.  Brief introduction to machine coordinate system and its accessories.  Brief introduction to machine operational manual and some crucial safety aspects pertaining the use of CNC Lathe machine. 3.) Introduction to CNC part programming To operate CNC machine tool, the first step is to understand the part drawing and produce a program manual script. The procedure for machining a part as shown below.

Figure 1:CNC programming Procedure

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Figure 2:Machine Control Panel     4.)   A. B. C. D. E. F. G. H. I. J.

Brief description of CNC part programming Understanding of various programming formats and emphasis on word address for Century Star CNC Lathe. Description of word addresses used in CNC. Structure and format of Part programs CNC part programming flow (CAD-CAM-Manual programming) Description of procedural flow of CAD to the final stage of production by material removal-programming is practically done manually. Stages of part programming are as follows CAD-CAD model is designed by either one of the methods as: CSG, Cell decomposition, primitive Instancing, Bezier curve, B-rep curves, etc. Interpretation of CAD orthographic projection-read & understand drawing in terms of dimension tolerances, surface finish, limits, operations and sequence of operations. Prepare program manual script-contains codes for machining, operations used, tool used, speed used, feed and Feedrate used. Transfer G-M codes to MCP keyboard. Mount tool to its respective position as it was programmed in manual script. Clamp billet/Work piece on spindle chuck and set tool start point either with tool data or WCS (G54-G59). Verify the condition of the part program on actual machine. If the program is ok, and no alarms given for syntax error, auto run cycle to produce the part. Once machining is done, before unclamping the part, check for the dimensional accuracy. If ok, dispatch product to the quality assurance department-metrology lab for further examination of surface finish, tolerance, hardness etc.

SIMPLE OPERATIONAL PROCEDURE FOR CNC LATHE 20 | D a l k r i n s T e c h n o l o g i e s C N C T u t o r i a l f o r b e g i n n e r s

Note: Before & during machining, every student is advised to observe workshop safety practices and cleanliness. A) Machine status:   

Check level of lubricant-it should not be above H-level or below L-level. Check coolant-it should come out of nozzle with high pressure and it should also be thick and whitish. Check that Emergence button is pressed on ...