[CNC Milling Report_2010]

TITLE
 Uses Of CNC Machine

A milling machine is a machine tool used to machine solid materials. Milling

machines exist in two basic forms: horizontal and vertical, which terms refer to the

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orientation of the cutting tool spindle. Unlike a drill press, in which the workpiece is
held stationary and the drill is moved vertically to penetrate the material, milling
also involves movement of the workpiece against the rotating cutter, the latter of
which is able to cut on its flanks as well as its tip. Workpiece and cutter movement
are precisely controlled to less than 0.001 in (0.025 mm), usually by means of
precision ground slides and leadscrews or analogous technology. Milling machines
may be manually operated, mechanically automated, or digitally automated via
computer numerical control (CNC).

Milling machines can perform a vast number of operations, some very complex,
such as slot and keyway cutting, planing, drilling, diesinking, rebating, routing, etc.
Cutting fluid is often pumped to the cutting site to cool and lubricate the cut, and to
sluice away the resulting swarf.

Most CNC milling machines (also called machining centers) are computer controlled vertical
mills with the ability to move the spindle vertically along the Z-axis. This extra degree of
freedom permits their use in diesinking, engraving applications, and 2.5D surfaces such as relief
sculptures. When combined with the use of conical tools or a ball nose cutter, it also significantly
improves milling precision without impacting speed, providing a cost-efficient alternative to
most flat-surface hand-engraving work.

Five-axis machining center with rotating table and computer interface

CNC machines can exist in virtually any of the forms of manual machinery, like horizontal mills.
The most advanced CNC milling-machines, the multiaxis machine, add two more axes in
addition to the three normal axes (XYZ). Horizontal milling machines also have a C or Q axis,
allowing the horizontally mounted workpiece to be rotated, essentially allowing asymmetric and
eccentric turning. The fifth axis (B axis) controls the tilt of the tool itself. When all of these axes
are used in conjunction with each other, extremely complicated geometries, even organic
geometries such as a human head can be made with relative ease with these machines. But the
skill to program such geometries is beyond that of most operators. Therefore, 5-axis milling
machines are practically always programmed with CAM.

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OBJECTIVE

Each an every student will be having their own objective for it to makes their project or learning
process to be done well and correctly. Regarding this, there’s some main objective which thought
the student like me to successful up my project of CNC MILLING.

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♦ Learn what’s the uses of G-CODE in which we

learn how to interpret the given figure into a G-
CODE scale reading.

♦ Learn how to make over a project before it’s done

by a machine. Some process will take over here
through SIMULATION by using EXSL WIN 7
software in computer.

♦ Get to know the sizes and uses of the milling

cutter(cutting tool).

♦ Student learns how to change milling cutter(cutting

tool).

♦ Operation of CNC machine can be learn by the

student.

INTRODUCTION
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 World of CNC

In

Industry it is not efficient or profitable to make everyday products by hand. On a CNC machine
it is possible to make hundreds or even thousands of the same item in a day. First a design is
drawn using design software, then it is processed by the computer and manufactured using the
CNC machine. The machine featured below is the BOXFORD DUET. This is a small CNC
machine and can be used to machine woods, plastics and aluminium. In industry, CNC machines
can be extremely large. The Duet is one of the smaller CNCs and is ideal for use in schools.

VICE: This holds the material to be cut or shaped. Material must be held securely
otherwise it may 'fly' out of the vice when the CNC begins to machine. Normally
the vice will be like a clamp that holds the material in the correct position.

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GUARD: The guard protects the person using the CNC. When the CNC is machining the
material small pieces can be 'shoot' off the material at high speed. This could be
dangerous if a piece hit the person operating the machine. The guard completely
encloses the the dangerous areas of the CNC.
CHUCK: This holds the material that is to be shaped. The material must be placed in it very
carefully so that when the CNC is working the material is not thrown out at high
speed.
MOTOR: The motor is enclosed inside the machine. This is the part that rotates the chuck at
high speed.
LATHE BED: The base of the machine. Usually a CNC is bolted down so that it cannot move
through the vibration of the machine when it is working.

CUTTER: This is usually made from high quality steel and it is the part that actually cuts the
material to be shaped.

 Technology of CNC

1810s-1830s

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Milling machines evolved from the practice of rotary filing. That is, running a circular cutter
with file-like teeth in the headstock of a lathe. Both rotary filing and later true milling were
developed in order to reduce the time and effort spent on hand-filing. The full, true story of
the milling machine's development will probably never be known, because much of the early
development took place in individual shops where generally no one was taking down records
for posterity. However, the broad outlines are known. Rotary filing long predated milling.

1840s-1860s

Some of the key men in milling machine development during this

era. During this era there was a continued blind spot in milling
machine design, as various designers failed to develop a truly
simple and effective means of providing slide travel in all three of
the archetypal milling axes (X, Y, and Z—or as they were known in
the past, longitudinal, traverse, and vertical). Vertical positioning
ideas were either absent or underdeveloped.

1860s
In 1861, Frederick W. Howe asked Joseph R. Brown of Brown & Sharpe for a solution to the
problem of milling spirals, such as the flutes of twist drills. These were filed by hand at the
time. Brown designed a "universal milling machine" that, starting from its first sale in March
1862, was wildly successful. It solved the problem of 3-axis (XYZ) travel much more
elegantly than had been done in the past, and it allowed for the milling of spirals using an
indexing head fed in coordination with the table feed. The term "universal" was applied to it
because it was ready for any kind of work and was not as limited in application as previous
designs. (Howe had designed a "universal miller" in 1852, but Brown's of 1861 is the one
considered a groundbreaking success.)

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1870s-1930s

Two firms which most dominated the milling machine field during these
decades were Brown & Sharpe and the Cincinnati Milling Machine Company.
However, hundreds of other firms built milling machines during this time, and
many were significant in one way or another. The archetypal workhorse milling
machine of the late 19th and early 20th centuries was a heavy knee-and-
column horizontal-spindle design with power table feeds, indexing head, and a stout
overarm to support the arbor. Around the end of World War I, machine tool control
advanced in various ways that laid the groundwork for later CNC technology.
The jig borer popularized the ideas of coordinate dimensioning working routinely in
"tenths" as an everyday machine capability; and using the control to go straight
from drawing to part, circumventing jig-making. In 1920 the new tracer design
of J.C. Shaw was applied to Keller tracer milling machines for die-sinking via the
three-dimensional copying of a template. This made diesinking faster and
easier just as dies were in higher demand than ever before, and was very
helpful for large steel dies such as those used to stamp sheets in automobile
manufacturing. Such machines translated the tracer movements to input for servos
that worked the machine leadscrews or hydraulics.

1940s-1970s

By 1940, automation via cams, such as in screw machines and

automatic chuckers, had already been very well developed for
decades. These were soon combined with the emerging technology
of digital computers. During the 1950s, numerical control made its
commercial appearance. The technology transfer drastically
advanced machine tool control, and deeply transformed the
culture of manufacturing. During the 1960s and 1970s, NC
evolved into CNC, data storage and input media evolved,
computer processing power and memory capacity steadily
increased, and NC and CNC machine tools gradually
disseminated from the level of huge corporations to the level
of medium-sized corporations.

1980s-Present
Computers and CNC machine tools continue to develop rapidly. The PC
revolution has a great impact on this development. By the late 1980s small

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machine shops had desktop computers and CNC machine tools. After that
hobbyists began obtaining CNC mills and lathes.

 Advantage and Disadvantage of CNC

Advantages
Efficiency - Aside from the need for periodic maintenance, CNC machines
can operate almost continuously. One person can oversee the
operation of several CNC machines at a time.

Easy Use - CNC machines are easier for beginners to use than lathes and
milling machines.

Expanding - Software changes and updates make it possible to expand the

Options machine's capabilities rather than replacing the machine.

No - New designs and parts can be programmed directly into a

Prototype CNC machine, eliminating the need to build a prototype.

Disadvantages
Price - CNC machines are more expensive than manually operated
machines, although slowly coming down.
Skills - The CNC machine operator only needs basic training and
skills, enough to supervise several machines. In years gone by,
engineers needed years of training to operate centre
lathes, milling machines and other manually operated
machines. This means many of the old skills are been lost.

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Workers - Less workers are required to operate CNC machines
compared to manually operated machines.
Investment in CNC machines can lead to
unemployment.
Teaching - Many countries no longer teach pupils / students how to
use manually operated lathes / milling machines etc...
Pupils / students no longer develop the detailed skills
required by engineers of the past. These include
mathematical and engineering skills.

Theory
G-Code, or preparatory code or function, are functions in the Numerical control
programming language. The G-codes are the codes that position the tool and do the
actual work, as opposed to M-codes, that manages the machine; T for tool-related
codes. S and F are tool-Speed and tool-Feed, and finally D-codes for tool
compensation.

G-codes are also called preparatory codes, and are any word in a CNC program that begins with
the letter 'G'. Generally it is a code telling the machine tool what type of action to perform, such
as:
• rapid move
• controlled feed move in a straight line or arc
• series of controlled feed moves that would result in a hole being bored, a workpiece cut
(routed) to a specific dimension. .
• change a pallet
• set tool information such as offset
There are other codes; the type codes can be thought of like registers in a computer

• X = Absolute position
• Y = Absolute position
• Z = Absolute position
• M = Referred to as a "Miscellaneous" function
• F = Feed rate

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• S = Spindle speed
• N = Line number
• R = Arc radius or optional word passed to a subprogram/canned cycle

M codes control the overall machine, causing it to stop, start, turn on coolant, etc., whereas other
codes pertain to the path traversed by cutting tools. Different machine tools may use the same
code to perform different functions; even machines that use the same CNC control.
• Partial list of M-Codes
 M00 = Program Stop (non-optional)
 M01 = Optional Stop, machine will only stop if operator selects this option
 M02 = End of Program
 M03 = Spindle on (CW rotation)
 M04 = Spindle on (CCW rotation)
 M05 = Spindle Stop
 M06 = Tool Change
 M07 = Coolant on (flood)
 M08 = Coolant on (mist)
 M09 = Coolant off
 M10 = Pallet clamp on
 M11 = Pallet clamp off
 M30 = End of program/rewind tape (required for older CNC machines)

Common FANUC G Codes for Mill

 G00 = Rapid positioning
 G01 = Linear interpolation
 G02 = Clockwise circular interpolation
 G03 = Counter Clockwise circular interpolation
 G90 = Absolute programming (type B and C systems)
 G91 = Incremental programming (type B and C systems)

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Tools
1. Machine Of CNC MILLING

♦ Used to cut off the work piece as we stated in the G-CODE

program

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2. Milling cutter(Cutting tools)

Used

to cut the work piece as we want in which the milling cutter comes in various size
with its diameter.

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3. Cutter/Tool Holder

♦ Used to hold the milling cutter tightly because it will be

spining in high speed.

4. Vernier Caliper

♦ Used to measure the size of milling cutter(cutting tool)

manualy.

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5. Opener

♦ Use to tighten and unlock the nut which will hold the work
piece.

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6. Brush

♦ Used to clean up the wastage of work piece which has been

cuuten off from it.

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PROCEDURE OF PROJECT

 Steps Involved in SIMULATION by using (EXCL WIN 7)

1. Program of EXCL WIN 7 is clicked.

2. Then Project is clicked once its fully loaded.

3. Management is choosen and then New Project.

4. Choose Project Name : Example (HaRThi)

5. Then Fanuc OTC is clicked from the entire list, click Apply once done.

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6. The common code such as M Code and G Code is typed from the beginning until the
end.

7. Once done, its Save As(Using Same Programme Number: O0001;)

8. Once save, chose Edit on the right hand side of the program.

9. Then select Empty Tool Changer.

10. Select Changer 24 and click Load

11. Select the most suitable tools (Example: End Mill d : 3mm)

12. Click to insert the tool in the correct T

13. Click Corrections, then Measure and Close.

14. Blank is clicked select The Blank Profile : Square Bar

15. Insert the value of work piece from its Length, width and height and click OK.

16. Zero Reference Point is clicked and its Origin is stated.

17. Once all done, Select Simulation and then Full Sequence to view your work piece
with its project on it.

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 Steps Involved in CUTTING process by using BRIDGEPORT

VMX 600X

1. All of the instrument such as milling cutter(cutting tool), work piece and
needed material with its tools are placed.

2. Main switch of power is switched on.

3. Air Compressor which needed to power up the

machine is switched on. Its used when changing the Cutting Tool.

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4. Switch on machine is on press at NC Panel. Wait until the monitor shows

its functions.

5. Pull “Emergency Stop” and Press “Power On” button.

6. On screen will be shown “Machine Not Reference”. Press button “JOG”,

“REF RETURN” and “CYCLE START”.

7. Once the machine is start on, monitor will be showing “Spindle Warm
Up”.

8. Press button “REF RETURN” and “Spindle %S” on the same time.

9. Insert the program by manually key in it or insert by using computer

10. Use the new program name By EDIT – PROG – DIR- Insert the program
number as O0013;

11. Then press + on screen. Press READ – EXEC(LSK will be blinking)

12. On computer, make sure its at EDIT – DATA TRANSFER – choose FILE
NAME of the program which insert and press START.

13. For work piece setting, press “HANDLE” for using “hand wheel” to
manually movement.

14. Bring the pointer to the work piece on the coordinate of Z. Press
WORKSHIFT”. Take the reading, example -467.018 and radius 2.000.

15. Adjust the coordinate of X by bringing the milling cutter towards the work
piece. Press WORKSHIFT”. Take the reading, example -467.018 and the radius
2.000 is been minus. Its enter on the place of G54.

16. Repeat the steps 10 for Y coordinates(example -434.012). Example as

below.

X -465.018

Y -432.012

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17. To see the coordinate X, Y and Z, bring the milling cutter(cutting tool) to
the work piece by using “hand wheel”.

18. Once u are confidence of its coordinate ORIGIN and press “POS”, and
then click X. X will be blinking and press ORIGIN.

19. Repeat the steps of 15 for Y and Z.

20. “PROG”

21. “AUTO” “CYCLE START”.

22. Cutting process will start on.

23. Close the machine once the work piece is taken out and clean up the
machine before close it.

24. P

ress “Emergency Stop” and main switch is switched off.

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PROJECT OUTCOMES
Coordinates of the work piece of “XP LOGO” based on the graph paper.

COOR
DINAT
No. ES
X Y R
1 10 20
2 25 25 20
3 40 20 20
4 45 50
5 30 55 20
6 15 50 20
7 10 20
8 45 18
9 60 13 20
10 75 18 20
11 80 48

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12 65 43 20
13 50 48 20
14 45 18
15 51 53
16 66 48 20
17 81 53 20
18 86 83
19 71 78 20
20 56 83 20
21 51 53
22 46 55
23 51 85
24 36 90 20
25 21 85 20
26 16 55
27 31 60 20
28 46 55 20

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Simulation code of G90

O0001;
N10 G00 G90 G54 G40 G49 G80 G17 G21;
N20 M06 T1;
N30 G00 G43 H01 D1 Z10.;
N40 M03 S1600;
N50 G00 X10. Y20. Z10.;
N60 G01 Z-5. F300.;
N70 G02 X25. Y25. R20.;
N80 G02 X40. Y20. R20.;
N90 G01 X45. Y50.;
N100 G03 X30. Y55. R20.;
N110 G03 X15. Y50. R20.;
N120 G01 X10. Y20.;
N130 G00 Z100.;
N140 G00 X45. Y18. Z10.;
N150 G01 Z-5. F300.;
N160 G03 X60. Y13. R20.;
N170 G03 X75. Y18. R20.;
N180 G01 X80. Y48.;
N190 G02 X65. Y43. R20.;
N200 G02 X50. Y48. R20.;

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N210 G01 X45. Y18.;
N220 G00 Z100.;
N230 G00 X51. Y53. Z10.;
N240 G01 Z-5. F300.;
N250 G03 X66. Y48. R20.;
N260 G03 X81. Y53. R20.;
N270 G01 X86. Y83.;
N280 G02 X71. Y78. R20.;
N290 G02 X56. Y83. R20.;
N300 G01 X51. Y53.;
N310 G00 Z100.;
N320 G00 X46. Y55. Z10.;
N330 G01 Z-5. F300.;
N340 G01 X51. Y85.;
N350 G03 X36. Y90. R20.;
N360 G03 X21. Y85. R20.;
N370 G01 X16. Y55.;
N380 G02 X31. Y60. R20.;
N390 G02 X46. Y55. R20.;
N400 M05;
N410 M30;

Work Method

1. The design is loaded into the computer which is attached to the CNC machine.
The computer changes the design into a special code (numerical) that controls the
way the CNC cuts and shapes the material.

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2. The material to be cut is place in the machine. This

must be done carefully so that it does not come off the block during machining.

3. The block is then placed in the vice, inside the CNC. It must be

tightened up carefully. If it is not secure when the machine starts to cut the material
it can come away from the vice. When the machine starts working, the vice moves
up, down, right and left according to the design.

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4. The guard is placed in position. It protects the

machine operator in case the material is pulled out of the vice by the power of the
cutter. For safety reasons, if the guard is not in position the motor will not start.

5. The CNC is turned on and the shape is cut from the material. When the cutter has
stopped the shaped material can be removed from the vice. Total time - for simple
designs - 15 minutes.

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Project Done

1. 2.

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3. 4.

5.

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6.

Discussion

Problems Which Are Faced while using SIMULATION software

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♦ Being hard to find up all over the net and books for the figure of our
individual project with the specification that the lecturer wanted.

♦ It’s confusing when student want to interpret the data into the form of G-
CODE.

♦ Problem occurs when student want to find up the radius of sum arc or
circle seems they don’t know how to calculate over it.

♦ It’s not as easy to understand up all of the input in the software

♦ There a lot of static button with its function on our work piece.

♦ Moreover, the outcomes will be slacked if the inputs from the user are
wrong enough.

Suitable Solution Based on the Problems Raised

♦ Based on the problems of finding the right figure to make it as project,

there should be more open idea needed. Student should be creative and
innovative.

♦ The coordinates of each point should be taken to make them easier to

understand up the sequence.

♦ Regarding the radius and its arc circumference, they should be count up all
the length of the point.

♦ With the reference paper of “PROCEDURE USING EXSL WIN 7”, all
the problems can be clear off.

♦ The student should be key in the right code so that the output will be as
they want. Re-check their codes will solve the problem.

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Problems Which Are Faced will using CNC Machine

♦ There some G-CODE in which should be correctly key in so that the

cutting process will be running smoothly.

♦ Its quit complicating to find over the origin of X and Y axis once placed
into machine.

♦ Must be careful while using the HAND WHEEL

♦ Cutting tool should be in correct size.

Suitable Solution Based on the Problems Raised

♦ In this, the student can make over their simulation process first before
cutting take place so that they will get a clear view of the project they going to do.

♦ Bring the pointer to the work piece on the coordinate of Z. Take the
reading. Adjust the coordinate of X by bringing the milling cutter towards the
work piece then take the reading. The steps 10 for Y coordinate.

♦ Measure the size using vernier caliper before plug into the machine. Refer
to the given question if there’s was given its cutting tool size. If no then chose a
suitable size of cutting tool size.

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CONCLUSION

Safety Precaution

 When the student at the workshop, the safety is mainly advised so that any
mistakes happen. It’s make the student to be more safe even independent too.

 They should wear workshop uniform and safety boots which given by the
polytechnic.

 Gloves are advised to be wear before holding and after all work done it should be
removed.

 Place the matrix card on the pocket of workshop

uniform when handling with machines.

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Safety Boots

Workshop Uniform

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Comparing vertical with horizontal

Vertical milling machine.

1. Milling cutter
2. Spindle
3. Top slide or overarm
4. Column
5. Table
6. Y-axis slide
7. Knee
8. Base
In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle
and rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered,
giving the same effect), allowing plunge cuts and drilling. There are two subcategories of vertical
mills: the bed mill and the turret mill. Turret mills, like the ubiquitous Bridgeport, are generally
smaller than bed mills, and are considered by some to be more versatile. In a turret mill the
spindle remains stationary during cutting operations and the table is moved both perpendicular to

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and parallel to the spindle axis to accomplish cutting. In the bed mill, however, the table moves
only perpendicular to the spindle's axis, while the spindle itself moves parallel to its own axis.
Also of note is a lighter machine, called a mill-drill. It is quite popular with hobbyists, due to its
small size and lower price. These are frequently of lower quality than other types of machines,
however.

Horizontal milling machine.

1. Base
2. Column

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3. Knee
4 & 5. Table (x-axis slide is integral)
6. Overarm
7. Arbor (attached to spindle)
A horizontal mill has the same sort of x–y table, but the cutters are mounted on a horizontal arbor
(see Arbor milling) across the table. A majority of horizontal mills also feature a +15/-15 degree
rotary table that allows milling at shallow angles. While endmills and the other types of tools
available to a vertical mill may be used in a horizontal mill, their real advantage lies in arbor-
mounted cutters, called side and face mills, which have a cross section rather like a circular saw,
but are generally wider and smaller in diameter. Because the cutters have good support from the
arbor, quite heavy cuts can be taken, enabling rapid material removal rates. These are used to
mill grooves and slots. Plain mills are used to shape flat surfaces. Several cutters may be ganged
together on the arbor to mill a complex shape of slots and planes. Special cutters can also cut
grooves, bevels, radii, or indeed any section desired. These specialty cutters tend to be expensive.
Simplex mills have one spindle, and duplex mills have two. It is also easier to cut gears on a
horizontal mill.

Uses Of CNC Technology

Milling machines can perform a vast number of operations, some very complex,
such as slot

• Keyway Cutting

• Planning

• Drilling

• Die sinking

• Rebating

• Routing

Cutting fluid is often pumped to the cutting site to cool and lubricate the cut, and to
sluice away the resulting swarf.

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Project Based on OBJECTIVE

From the outcome, there some objective been taken to make over the project. There are some of
it as list down below;

I have been;

 Learned how to use G-CODE by interpret the given figure with its
scale.

 Learned how to use SIMULATION by using EXSL WIN 7 software in

computer.

 Able to learn how to adjust and operate the CNC MILLING machine
properly.

REFERENCE
Web Sites

• http://www.ehow.com/facts_4830778_advantages-cnc-
machines.html

• http://www.technologystudent.com/cam/cncman4.htm

• http://en.wikipedia.org/wiki/Milling_machine

• http://en.wikipedia.org/wiki/G-code

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• http://en.wikipedia.org/wiki/Milling_cutter#Features_of_a_mill
ing_cutter

Books

• Teknologi Worksyop – Abdul Rahman Darman

Lecturer

• Pn. Putri Irda Binti Abdul Rahman

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