N

TITLE
O.
1 CNC TURNING OF TAPERED
THREADED ALUMINIUM PART
2 EDM WIRE CUT OF V BLOCK
3 CNC MILLING OF A VIBRATION
SOCKET
4 RAPID PROTOTYPING : 3D
PRINTING IMPELLERS

LAB REPORT- CNC LAB DEMO

TEAM C
Name :
SITI NURAIMI BINTI ABDUL
HAMID
MATRIX NO :
120416

SCHOOL OF MECHANICAL
ENGINEERING

LECTURER:
YBHG. PROFESOR DATUK DR.
AHMAD
YUSOFF HASSAN

EPP 331 MANUFACTURING

TECHNOLOGY II

DATE OF SUBMISSION :
18 NOVEMBER 2015

Title : CNC Lab Demo

Introduction :
We have had full lab demo session on CNC Turning of Tapered Aluminium, EDM Wire Cut of V Blocks, CNC Milling of a
Vibration Socket and Rapid Prototyping 3D Printing of Impellers. We were able to see the demonstrations of the
component for each type of machine. The demonstration was conducted by the technician. We gained a lot of
information in the production of the components.
Objective :
1.
2.
3.
4.
5.
6.
7.

To
To
To
To
To
To
To

understand the practicalities of CNC machines

be aware of safety issues
identify the elements in the system
know the procedures and actual operations
carry out simple inspection and relevant analysis
realize the possible applications compared to various manufacturing processes
know the important parameters to define machines specifications and cost of purchase

Apparatus :
1.
2.
3.
4.

CNC Universal Turning CTX Alpha 300

Precision Wire-Cut EDM Sodick-AG400L
CNC 5-Axis DMU 40 Monoblock
Rapid Prototyping-Objet30 Scholar

Type of
Machine

CNC Turning of
Tapered Thread
Aluminium Part

EDM Wire Cut of V

Blocks

CNC Milling of a
Vibration Socket

Rapid Prototyping: 3D
Printing of Impellers

CNC Universal
Turning CTX Alpha
300

Precision Wire-Cut
EDM Sodick-AG400L

CNC 5-Axis DMU 40

Monoblock

Rapid PrototypingObjet30 Scholar

CNC stands for

Computer
Numerical
Control.
A computer rather
than operator will
directly control
the machine tool.

EDM stands for

electrical
discharge
machining.
It is a process of
using a thin
single-strand of
metal wire fed
through a work
piece.
Can be
programmed to
cut very
intricate and
delicate shapes.

a specific form of
computer numerical
controlled (CNC)
machining.
consists of a table
that moves in the Yaxis and a tool chuck
that moves in X and
Z(depth).

Rapid prototyping is
a group of
techniques used to
quickly fabricate a
scale model of a
physical part using
three-dimensional
computer aided
design (CAD)

System
of axes

X vertical
Y- milling
Z- horizontal

Sequenc
e of
steps

1. The dimension of
the design is key
in into the
controller . The
controller used
IGF Software to
generate G-code.
2. The work piece is
clamped onto the
hydraulic clamp.
3. The speed is set
to 50% mm/rev .
4. The CNC machine
turning started
layer by layer to
cut on the work
piece.

X, Y, Z axis travel
for (400X300X250)
mm
U, V axis travel for
(120X120) mm

1. Start a CNC EDM

wire cut machines
2. Write a CNC
program
3. Prepare a graphics
using AutoCAD
4. Perform a cutting
operation on the
work piece based
on programming
5. Stop the machine

1.
2.
3.
4.
5.
6.
7.
8.

X, Y, Z axis having
1181 ipm of rapid
rate
A and B axis has 35
rpm and 60 rpm of
rapid rate
respectively
Place the workpiece
on the table
Boot the CNC Milling
Machine
Insert endmill
Moving to X, Y, Z axis
Load files
Preview
Operating
Machine stop

Build

resolution :
X-axis : 300 mm
Y-axis : 200 mm
Z-axis : 100 mm

1. Fill in the model

material and the
support material in
the container
2. By using a drawing,
we can see it at a
desktop that
connect to the
printer
3. Set up the positions
of the product
perfectly to reduce
the time taken to
complete the
operations
4. Start printing and
wait until the

Operatio
ns

Time
Taken
VS
Simulate
d Time

Importan
t
Paramet
ers

Drilling
Center drilling
Milling
Grooving
Roughing
Parting
Finishing
threading

6 minute 4 second
VS
5 minute 57 second

Production rate
Surface finish
Cutting speed
Feed rate
Depth of cut
Surface
roughness

Drilling
Roughing
Skimming

30 minute 20 second
VS
22 minute 10 second

voltage parameter
current parameter
pulse related
parameters

End milling
Chamfer milling
Face milling
Drilling
Boring
Tapping

15 minutes 30 second
VS
15 minutes

Cutting feed - The

distance that the work
piece advances during
one revolution of the
spindle and tool

product produce
5. For finishing stage,
place the product in
the cleaner
Liquid layer curing
and milling
Extrusion of melted
plastic

Simulated time : 1 hour

40 minutes
No of
Time
part
Taken(min)
1
56
3
70
* the more number of
part, the longer time it
takes to print

Print Speed
Movement Speed
Retraction Distance
Retraction Speed
Number of Shells
Layer Height

Safety
Precautio
n

Students should
wearing cover
shoes , suitable
cloth during the
lab session .
During machining,
always make sure
the shielding door
of the machine is
covered. This to
avoid any flying
chips during

Make sure there

are no leaks in the
tank dielectric
liquid tank hose
and pipe
connections.

Cutting speed - The

speed of the work
piece surface relative
to the edge of the
cutting tool during a
cut

Spindle speed - The

rotational speed of the
spindle and tool in
revolutions per minute
(RPM).

Feed rate - The speed

of the cutting tool's
movement relative to
the workpiece as the
tool makes a cut.
Follow correct clamping
procedures- keep
overhangs as small as
possible and check work
piece is secure.
Set the correct speed to
suit the cutter diameter,
the depth of cut and the
material.

Layer Fan

Use gloves as we
exposed to the
chemical
substances

machining.
Advantag
es of the
machine

Software
used in
design
Machine
cost
Products

Less time needed

to produce a
product
More accurate
than manual
Can be use to
produce complex
shape

Design on the
computer
machine
RM 629 999

Any material that is

electrically
conductive can be
cut using the EDM
process.
Hardened
workpieces can be
machined
eliminating the
deformation
caused by heat
treatment.
Solid work
CATIA
RM 420 000

Build complex design

Complex machining
operations can be
perform easily

CATIA (save as .igf

file)

RM 900 000

Time and cost

saving
Allows us to build
extremely complex
objects more easily
and innovatively

CATIA (save as .stl

file)
RM 180 000

Discussion :
The desired objective have been successfully implemented. Any guidance given by the lecturer and technician are very
useful and effective. We know how to enter the program and run the machine for the design of the products made. All
the knowledge that we get was really useful for our final year project later on and also very helpful as we go into the
working world later.