PROJECT REPORT ON DESIGN & MANUFACTURING OF PIPE VICE 2-D PROFILE BY USING AUTO-CAD & CNC DESKTOP MILLING

MACHINE

ABSTRACT:
Designing of Pipe vice on a wooden piece using CNC desktop milling machine.

Features of Sinumerik Milling Machine :

It is a microprocessor CNC, continuous path control with integrated programmable logical control (PLC). The system has linear axes control with simultaneous interpolation of two axis .

Specifications of wood:
Type of wood: teak wood Length: 120mm Breadth: 120mm Width: 30mm

Specifications of Pipe vice:

X-axis: 88mm Y-axis: 91mm Z-axis: 2mm

Central Institute of Tool Design

The Institute for Enhancement of Technology

Motto

Established 1968 Type Autonomous Institute

Students Location Campus Acronym

1100 Hyderabad, Andhra Pradesh, India Urban, 10 acres (0.04 km) CITD

Micro Small and Medium Affiliations Enterprises, Osmania University,

JNTU

Website

www.citdindia.org

Central Institute of Tool Design or CITD is a premier institute in Asia providing specialized programs in Tool Engineering. CITD's main campus is located in Hyderabad, India with a branch campus in Vijayawada and an extension centre in Chennai.

History
The Institute was established in the year 1968 by the Government of India with the assistance of United Nations Development Programme (UNDP) and International Labour Organization (ILO) as an executing Agency.

Objective
The objective of the Institute is to meet the requirements of the Industries in the field of Tool Design and Manufacture and to train the technical personnel in these fields. The Institute has strong links with industries to impart practical knowledge by way of undertaking tooling assignments.

Facilities
The Institute has a well equipped Tool Room with sophisticated CNC machines like CNC EDM (CharmillesRoboform 54), CNC Wirecut EDM (AGIE Cut Classic-III & Electronics), 4-Axis & 5-Axis High-Speed Machining Centres, Kellenberger CNC Cylindrical Grinding Machine and 3D Coordinate Measuring Machine with Scanning and Digitization facilities. The Institute is equipped with latest versions of EMCO Table Top CNC Turning and Milling machines with dosed loop systems to impart training in CNC Programming. The Calibration laboratory is set up in CITD with Universal Horizontal metroscope ULM OPAL 600 Carl Zeiss Technology, Germany and Slip Gauge Measuring Unit 826 with Millitron 1240, Mahr, Germany, to Calibrate Limit Gauges, Micrometers, Dial Indicators, etc. The Automation Centre is equipped with various simulator training kits like Advanced Pneumatics Trainer, Advanced Electro Pneumatics Trainer with PID Controls, Advanced Hydraulics Trainer, Advanced Electro Hydraulics Trainer, Closed loop Hydraulics Trainer with PID Controls, PLC Trainer, Sensors Technology Trainer, Modular Production System with Testing, Processing, Handling and Sorting Stations, Cut Section models of various Elements, Transparent working models of Hydraulics element etc. The CAD/CAM Centre is equipped with latest hardware like Compaq workstations. IBM, DELL Systems, Pentium IV Systems and software like AutoCAD, MDT Ideas NX11, Pro-E wildfire, Catia V5, UG, Ansys, Nastran, Hypermesh, MasterCam, DelCam, SolidWork, Solid edge etc. The Institute has a special Library with collection of technical books in Tool Engineering field and subscribes to various International Journals like CIRP Annals, American Machinist, Journal of Engineering Materials & Technology (ASME), Precision Engineering (JAPAN) and Precision Tool Maker etc., The Documentation Centre collects and organizes information and data useful for the technological advancement in Tool Engineering. For the dissemination of information, the centre publishes a computerised current awareness abstracting bulletin and provides technical enquiry service.

AutoCAD
INTRODUCTION:

AutoCAD 2012

Developer(s) Initial release Stable release Operating system Type License Website

Autodesk December 1982 2012 / March 22, 2011; 2 months ago Windows, Mac OS X, iOS CAD Proprietary autodesk.com/autocad

AutoCAD is a CAD (Computer Aided Design or Computer Aided Drafting) software application for 2D and 3Ddesign and drafting. It is developed and sold by Autodesk, Inc.First released in December 1982, AutoCAD was one of the first CAD programs to run on personal computers, notably the IBM PC. At that time, most other CAD programs ran on mainframe computers or mini-computers which were connected to a graphics computer terminal for each user. Early releases of AutoCAD used primitive entities lines, poly lines, circles, arcs, and text to construct more complex objects. Since the mid-1990s, AutoCAD has supported custom objects through its C++ Application Programming Interface (API). Modern AutoCAD includes a full set of basic solid modeling and 3D tools. With the release of AutoCAD 2007 came improved 3D modeling, which meant better navigation when working in 3D. Moreover, it became easier to edit 3D models. The mental rayengine was included in rendering, it was now possible to do quality renderings. AutoCAD 2010 introduced parametric functionality and mesh modeling. AutoCAD supports a number of APIs for customization and automation. These include AutoLISP, Visual LISP, VBA, .NET and ObjectARX. ObjectARX is a C++ class library, which was also the base for products extending AutoCAD functionality to specific fields, to create products such as AutoCAD Architecture, AutoCAD Electrical, AutoCAD Civil 3D, or thirdparty AutoCAD-based applications.

AutoCAD and AutoCAD LT are available for English, German, French, Italian, Spanish, Japanese, Korean, Chinese Simplified, Chinese Traditional, Russian, Czech, Polish, Hungarian, Brazilian Portuguese, Danish, Dutch, Swedish, Finnish, Norwegian, and Vietnamese. The extent of localization varies from full translation of the product to documentation only. The AutoCAD command set is localized as a part of the software localization. Auto CAD Origin AutoCAD was derived from a program called Interact, which was written in a proprietary language (SPL) and ran on the Marinchip Systems 9900 computer (Marin chip was owned by Autodesk co-founders John Walker and Dan Drake.) When Marinchip Software Partners (later to be renamed Autodesk) was formed, they decided to re-code Interact in C and PL/1 -- C, because it seemed to be the biggest upcoming language. In the end, the PL/1 version was unsuccessful. The C version was, at the time, one of the most complex programs in that language to date. Autodesk even had to work with the compiler developer (Lattice) to fix certain limitations to get AutoCAD to run.

AutoCAD LT
AutoCAD LT is a lower cost version of AutoCAD with reduced capabilities first released in November 1993. AutoCAD LT, priced at $495, became the first product in the company's history priced below $1000 to bear the name "AutoCAD". In addition to being sold directly by Autodesk, it can also be purchased at computer stores, unlike the full version of AutoCAD which must be purchased from official Autodesk dealers. Autodesk developed AutoCAD LT so that they would have an entry-level CAD package to compete in the lower price level. As of the 2011 release the AutoCAD LT MSRP has risen to $1200. While there are hundreds of small differences between the full AutoCAD package and AutoCAD LT, currently there are a few recognized major differences in the software's features:
y y y y y

3D Capabilities: AutoCAD LT lacks the ability to create, visualize and render 3D models as well as 3D printing. Network Licensing: AutoCAD LT cannot be used on multiple machines over a network. Customization: AutoCAD LT does not support customization with LISP, ARX, and VBA. Management and automation capabilities with Sheet Set Manager and Action Recorder. CAD standards management tools.

AutoCAD Freestyle
Built on the AutoCAD platform, AutoCAD Freestyle is a simplified, low-cost (US$149) application that makes it easy to create accurate, professional-looking 2D drawings and sketches. This software has been discontinued by Autodesk.

Student versions
AutoCAD is licensed at a significant discount over commercial retail pricing to qualifying students and teachers, with a 36-month license available. The student version of AutoCAD is functionally identical to the full commercial version, with one exception: DWG files created or edited by a student version have an internal bit-flag set (the "educational flag"). When such a DWG file is printed by any version of AutoCAD (commercial or student), the output will include a plot stamp / banner on all four sides. Objects created in the Student Version cannot be used for commercial use. These Student Version objects will "infect" a commercial version DWG file if imported. The Autodesk student community provides registered students with free access to different Autodesk applications.

Vertical programs
Autodesk has also developed a few vertical programs, for discipline-specific enhancements. AutoCAD Architecture (formerly Architectural Desktop), for example, permits architectural designers to draw 3D objects such as walls, doors and windows, with more intelligent data associated with them, rather than simple objects such as lines and circles. The data can be programmed to represent specific architectural products sold in the construction industry, or extracted into a data file for pricing, materials estimation, and other values related to the objects represented. Additional tools allow designers to generate standard 2D drawings, such as elevations and sections, from a 3D architectural model. Similarly, Civil Design, Civil Design 3D, and Civil Design Professional allow data-specific objects to be used, allowing standard civil engineering calculations to be made and represented easily. AutoCAD Electrical, AutoCAD Civil 3D, AutoCAD Map 3D, AutoCAD Mechanical, AutoCAD MEP, AutoCAD P&ID, AutoCAD Plant 3D and AutoCAD Structural Detailing are other examples of industry-specific CAD applications built on the AutoCAD platform.

File formats
AutoCAD's native file format, DWG, and to a lesser extent, its interchange file format, DXF, have become de facto standards for CAD data interoperability. AutoCAD in recent years has included support for DWF, a format developed and promoted by Autodesk for publishing CAD data. In 2006, Autodesk estimated the number of active DWG files to be in excess of one billion. In the past, Autodesk has estimated the total number of DWG files in existence to be more than three billion.

This is the first article of my AutoCAD tutorial series. Since I have Revit and MicroStation tutorial for beginners, then I think, why not writing AutoCAD for beginners too? I know that there are many resources for learning AutoCAD, but I hope this is still useful. I have posted 8 steps you need to get through to mastering AutoCAD. This AutoCAD tutorial will be based on that article.

Changing the Workspace

Before we start, I want to make sure we all see the same AutoCAD interface, so if you dont see the same interface as we see in this image, click the workspace button in your AutoCAD, then select the 2D Drafting and Annotation. Click next button to see how to do it.

AutoCAD Interface Elements 1. Your AutoCAD drawing area. This is where you will drawing your AutoCAD objects. 2. AutoCAD Ribbon. This is where you can access AutoCAD tools and settings. 3. AutoCAD Ribbon has several tabs. Each tab holds AutoCAD tools based on your drawing task. For example, we can use drawing tools and modify tools in home tab. But when we need to add text and dimensions, we need to open the Annotate tab. When we need to insert blocks, we need to move to insert tab. 4. In each tab have several panels. This panels have similar AutoCAD tools inside them. 5. Command Line. We can activate tools and change the tool settings by typing in command line. Command line is also providing information what you should do next. 6. Drafting Settings. While we draw, we need to change some drafting settings. This is where you can change it. 7. The AutoCAD logo. Click it once (do not click it twice, as doing it will end your AutoCAD session). 8. AutoCAD will show you the AutoCAD menu. Some will say application menu, since the application name is AutoCAD, I prefer to call it AutoCAD menu :) This is where you can access tools related to applications, such as saving files.

The Basic of Using AutoCAD Drawing Tools

This time we are going to learn how to use AutoCAD drawing tools. I will not describe how you can use every tools, but how to use AutoCAD drawing tools in general. My objective is you know how to learn AutoCAD by yourself. I can write how to use every AutoCAD tools, but dont you think understanding it is better?
Using AutoCAD Drawing tools is simple

Theres nothing hard in using AutoCAD drawing tools. Lets try this simple steps. You can see the screenshot below, click next/forward button to move to the next step.
1. Click the tool you want to use on the ribbon. AutoCAD drawing tools is on home tab. Lets start with line. 2. You will see the dynamic input near your pointer. It will tell you what you need to do next. Most of drawing tools will ask you a point location. We will learn how to input the coordinate precisely later. Just click anywhere on your drawing area. 3. Again, dynamic input will tell you what to do. Another point location. Click anywhere again. Pay attention that information in dynamic input is also shown in command line. 4. AutoCAD is continue asking you for point location. Click again. 5. When you finish drawing line segments, press [enter] to finish it. Many veteran AutoCAD users like to use [space] as an alternative. 6. Now lets try to draw a rectangle. 7. Just like drawing lines, it will ask you for a point location. Click anywhere. 8. And just like line tool, it will ask next point. But dont click your mouse yet. Press down arrow on your keyboard, or click the small arrow next to specify other corner point or 9. This is how you can see options for creating rectangle. The most common way is defining 2 points, but you can also define it by using other methods. If you see in the command line, you can see the options too. You can use the option by typing the capital letters in available options.

OMPUTER NUMERICAL CONTROL (CNC)C

History
Earlier forms of automation

The automation of machine tool control began in the 19th century with cams that "played" a machine tool in the way that cams had long been playing musical boxes or operating elaborate cuckoo clocks. Thomas Blanchard built his gun-stock-copying lathes (1820s-30s), and the work of people such as Christopher Miner Spencer developed the turret lathe into the screw machine (1870s). Cam-based automation had already reached a highly advanced state by World War I (1910s). However, automation via cams is fundamentally different from numerical control because it cannot be abstractly programmed. Cams can encode information, but getting the information from the abstract level of an engineering drawing into the cam is a manual process that requires sculpting and/or machining and filing. Various forms of abstractly programmable control had existed during the 19th century: those of the Jacquard loom, player pianos, and mechanical computers pioneered by Charles Babbage and others. These developments had the potential for convergence with the automation of machine tool control starting in that century, but the convergence did not happen until many decades later. The application of hydraulics to cam-based automation resulted in tracing machines that used a stylus to trace a template, such as the enormous Pratt & Whitney "Keller Machine", which could copy templates several feet across.[1] Another approach was "record and playback", pioneered at General Motors (GM) in the 1950s, which used a storage system to record the movements of a human machinist, and then play them back on demand. Analogous systems are common even today, notably the "teaching lathe" which gives new machinists a hands-on feel for the process. None of these were numerically programmable, however, and required a master machinist at some point in the process, because the "programming" was physical rather than numerical.

Today
Although modern data storage techniques have moved on from punch tape in almost every other role, tapes are still relatively common in CNC systems. Several reasons explain this. One is easy backward compatibility of existing programs. Companies were spared the trouble of re-writing existing tapes into a new format. Another is the principle, mentioned earlier, that individual firms tend to stick with whatever is profitable, and their time and money for trying out alternatives is limited. A small firm that has found a profitable niche may keep older equipment in service for years because "if it ain't broke [profitability-wise], don't fix it." Competition places natural limits on that approach, as some amount of innovation and

continuous improvement eventually becomes necessary, lest competitors be the ones who find the way to the "better mousetrap". One change that was implemented fairly widely was the switch from paper to mylar tapes, which are much more mechanically robust. Floppy disks, USB flash drives and local area networking have replaced the tapes to some degree, especially in larger environments that are highly integrated. The proliferation of CNC led to the need for new CNC standards that were not encumbered by licensing or particular design concepts, like APT. A number of different "standards" proliferated for a time, often based around vector graphics markup languages supported by plotters. One such standard has since become very common, the "G-code" that was originally used on Gerber Scientific plotters and then adapted for CNC use. The file format became so widely used that it has been embodied in an EIA standard. In turn, while G-code is the predominant language used by CNC machines today, there is a push to supplant it with STEP-NC, a system that was deliberately designed for CNC, rather than grown from an existing plotter standard. While G-code is the most common method of programming, some machine-tool/control manufacturers also have invented their own proprietary "conversational" methods of programming, trying to make it easier to program simple parts and make set-up and modifications at the machine easier (such as Mazak's Mazatrol and Hurco). These have met with varying success. Since about 2006, the idea has been suggested and pursued to foster the convergence with CNC and DNC of several trends elsewhere in the world of information technology that have not yet much affected CNC and DNC. One of these trends is the combination of greater data collection (more sensors), greater and more automated data exchange (via building new, open industrystandard XML schemas), and data mining to yield a new level of business intelligence and workflow automation in manufacturing. Another of these trends is the emergence of widely published APIs together with the aforementioned open data standards to encourage an ecosystem of user-generated apps and mashups, which can be both open and commercial in other words, taking the new IT culture of app marketplaces that began in web development and smartphone app development and spreading it to CNC, DNC, and the other factory automation systems that are networked with the CNC/DNC. MTConnect is a leading effort to bring these ideas into successful implementation.

Description
Modern CNC mills differ little in concept from the original model built at MIT in 1952. Mills typically consist of a table that moves in the X and Y axes, and a tool spindle that moves in the Z (depth). The position of the tool is driven by motors through a series of step-down gears in order to provide highly accurate movements, or in modern designs, direct-drive stepper motors. Closed-loop control is not mandatory today, as open-loop control works as long as the forces are kept small enough.

As the controller hardware evolved, the mills themselves also evolved. One change has been to enclose the entire mechanism in a large box as a safety measure, often with additional safety interlocks to ensure the operator is far enough from the working piece for safe operation. Most new CNC systems built today are completely electronically controlled.CNC-like systems are now used for any process that can be described as a series of movements and operations. These include laser cutting, welding, friction stir welding, ultrasonic welding, flame and plasma cutting, bending, spinning, pinning, gluing, fabric cutting, sewing, tape and fiber placement, routing, picking and placing (PnP), and sawing.

Tools with CNC variants

y y y y y y y y y y y y y y y y

Drills EDMs Lathes Milling machines Wood routers Sheet metal works (Turret Punch) Wire bending machines Hot-wire foam cutters Plasma cuttings Water jet cutters Laser cutting Oxy-fuel Surface grinders Cylindrical grinders 3D Printing Induction hardening machines[citation needed]

Numerical control

A CNC Turning Center.

Siemens CNC panel.

Numerical control (NC) refers to the automation of machine tools that are operated by abstractly programmed commands encoded on a storage medium, as opposed to manually controlled via handwheels or levers, or mechanically automated via cams alone. The first NC machines were built in the 1940s and 1950s, based on existing tools that were modified with motors that moved the controls to follow points fed into the system on punched tape. These early servomechanisms were rapidly augmented with analog and digital computers, creating the modern computer numerical control (CNC) machine tools that have revolutionized the machining processes. In modern CNC systems, end-to-end component design is highly automated using computeraided design (CAD) and computer-aided manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a postprocessor, and then loaded into the CNC machines for production. Since any particular component might require the use of a number of different tools-drills, saws, etc., modern machines often combine multiple tools into a single "cell". In other cases, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine. In either case, the complex series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD design.

Advantages
Accuracy When programmed correctly, CNC machines are usually 100% correct with what they produce. They:

Disdvantages
Cost As with any business, costs are always a factor. CNC machinery:
y

y y y

produce parts to maximise accuracy provide good positional accuracy and repeatability provide a high degree of quality because of their accuracy and their ability to reuse programs.

y y

costs quite a lot more than conventional machinery does not eliminate the need for expensive tools parts (ie machines and tooling) are costly and their purchase requires extensive justification. is expensive to repair.

Simplicity CNC machines are not all that difficult to use once you learn how. For example:
y y y y

Errors CNC machines do not totally eliminate errors. Operators can still push the wrong

buttons, make incorrect alignments and fail complex jigs and fixtures are not required in all areas to locate parts properly on a jig. since fewer jigs are used, the actual storage requirements are reduced lower tooling costs since there is less need for complex jigs and fixtures once the first piece has passed inspection, minimal inspection is required on subsequent parts advanced machine control and programming capabilities allow for complex machining operations to be more easily accomplished.

Time Using CNC machines effectively reduces the amount of time take to produce furniture items. CNC machines:
y

enable the operator to make changes or improvements with a minimum of delay or expense reduce waste as errors due to operator fatigue, interruptions and other factors are less likely to occur improve production planning as they can often perform work at one setting that would normally require several conventional machines reduce lead time as a result of lower tooling costs.

Milling and turning CNC machines:

MILLING MACHINES:
A milling machine (also see synonyms below) is a machine tool used to machinesolidmaterials. Milling machines are often classed in two basic forms, horizontal and vertical, which refers to the orientation of the main spindle. Both types range in size from small, bench-mounted devices to room-sized machines. Unlike a drill press, which holds the workpiece stationary as the drill moves axially to penetrate the material, milling machines also move the workpiece radially against the rotating milling cutter, which cuts on its sides 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, from simple (e.g., slot and keyway cutting, planing, drilling) to complex (e.g., contouring, diesinking). Cutting fluid is often pumped to the cutting site to cool and lubricate the cut and to wash away the resulting swarf.

History:
The history of milling cutters is intimately bound up with that of milling machines. Milling evolved from rotary filing, so there is a continuum of development between the earliest milling cutters known, such as that of Jacques de Vaucanson from about the 1760s or 1770s,[2][3] through the cutters of the milling pioneers of the 1810s through 1850s (Whitney, North, Johnson, Nasmyth, and others), to the cutters developed by Joseph R. Brown of Brown & Sharpe in the 1860s, which were regarded as a break from the past for their large step forward in tooth coarseness and for the geometry that could take successive sharpenings without losing the form of the cut. De Vries (1910) reported, "This revolution in the science of milling cutters took place in the States about the year 1870, and became generally known in Europe during the Exhibition in Vienna in 1873. However strange it may seem now that this type of cutter has been universally adopted and its undeniable superiority to the old European type is no longer doubted, it was regarded very distrustfully and European experts were very reserved in expressing their judgment. Even we ourselves can remember that after the coarse pitched cutter had been introduced, certain very clever and otherwise shrewd experts and engineers regarded the new cutting tool with many a shake of the head. When[,] however, the Worlds Exhibition at Philadelphia in 1876, exhibited to European experts a universal and many-sided application of the coarse pitched milling cutter which exceeded even the most sanguine expectations, the most far-seeing engineers were then convinced of the immense advantages which the application of

the new type opened up for the metalworking industry, and from that time onwards the American type advanced, slowly at first, but later on with rapid strides". Woodbury provides citations of patents for various advances in milling cutter design, including irregular spacing of teeth (1867), forms of inserted teeth (1872), spiral groove for breaking up the cut (1881), and others. He also provides a citation on how the introduction of vertical mills brought about wider use of the end mill and fly cutter types

Features of a milling cutter

An End Mill cutter with two flutes Milling cutters come in several shapes and many sizes. There is also a choice of coatings, as well as rake angle and number of cutting surfaces.

y y

Shape: Several standard shapes of milling cutter are used in industry today, which are explained in more detail below. Flutes / teeth: The flutes of the milling bit are the deep helical grooves running up the cutter, while the sharp blade along the edge of the flute is known as the tooth. The tooth cuts the material, and chips of this material are pulled up the flute by the rotation of the cutter. There is almost always one tooth per flute, but some cutters have two teeth per flute.[1] Often, the words flute and tooth are used interchangeably. Milling cutters may have from one to many teeth, with 2, 3 and 4 being most common. Typically, the more teeth a cutter has, the more rapidly it can remove material. So, a 4-tooth cutter can remove material at twice the rate of a 2-tooth cutter. Helix angle: The flutes of a milling cutter are almost always helical. If the flutes were straight, the whole tooth would impact the material at once, causing vibration and reducing accuracy and surface quality. Setting the flutes at an angle allows the tooth to enter the material gradually, reducing vibration. Typically, finishing cutters have a higher rake angle (tighter helix) to give a better finish. Center cutting: Some milling cutters can drill straight down (plunge) through the material, while others cannot. This is because the teeth of some cutters do not go all the way to the centre of the end face. However, these cutters can cut downwards at an angle of 45 degrees or so. Roughing or Finishing: Different types of cutter are available for cutting away large amounts of material, leaving a poor surface finish (roughing), or removing a smaller amount of material, but leaving a good surface finish (finishing). A roughing cutter may have serrated teeth for breaking the chips of material into smaller pieces. These teeth leave a rough surface behind. A finishing cutter may have a large number (4 or more) teeth for removing material carefully. However, the large number of flutes leaves little room for efficient swarf removal, so they are less appropriate for removing large amounts of material.

Coatings: The right tool coatings can have a great influence on the cutting process by increasing cutting speed and tool life, and improving the surface finish. Polycrystalline Diamond (PCD) is an exceptionally hard coating used on cutters which must withstand high abrasive wear. A PCD coated tool may last up to 100 times longer than an uncoated tool. However the coating cannot be used at temperatures above 600 degrees C, or on ferrous metals. Tools for machining aluminium are sometimes given a coating of TiAlN. Aluminium is a relatively sticky metal, and can weld itself to the teeth of tools, causing them to appear blunt. However it tends not to stick to TiAlN, allowing the tool to be used for much longer in aluminium.

Shank: The shank is the cylindrical (non-fluted) part of the tool which is used to hold and locate it in the tool holder. A shank may be perfectly round, and held by friction, or it may have a Weldon Flat, where a grub screw makes contact for increased torque without the tool slipping. The diameter may be different from the diameter of the cutting part of the tool, so that it can be held by a standard tool holder.

Types and nomenclature

Mill orientation is the primary classification for milling machines. The two basic configurations are vertical and horizontal. However, there are alternate classifications according to method of control, size, purpose and power source.

Mill orientation
Vertical mill 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.
y

A turret mill has a stationary spindle and the table is moved both perpendicular and parallel to the spindle axis to accomplish cutting. The most common example of this type is the Bridgeport, described below. Turret mills often have a quill which allows the milling cutter to be raised and lowered in a manner similar to a drill press. This type of machine provides two methods of cutting in the vertical (Z) direction: byraising or lowering the quill, and by moving the knee.

DIFFERENT TYPES OF MILLING MACHINES

y

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.

Turret mills are generally considered by some to be more versatile of the two designs. However, turret mills are only practical as long as the machine remains relatively small. As machine size increases, moving the knee up and down requires considerable effort and it also becomes difficult to reach the quill feed handle (if equipped). Therefore, larger milling machines are usually of the bed type. 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. A mill-drill is similar to a small drill press but equipped with an X-Y table. These are frequently of lower quality than other types of machines. Horizontal mill Horizontal milling machine. 1: base 2: column 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 xy table, but the cutters are mounted on a horizontal arbor (seeArbor milling) across the table. Many horizontal mills also feature a built-in rotary table that allows milling at various angles; this feature is called a universal table. 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 and have a larger cross-sectional area than an end mill, 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. Some horizontal milling machines are equipped with a power-take-off provision on the table. This allows the table feed to be synchronized to a rotary fixture, enabling the milling of spiral features such as hypoid gears.

End mill

Slot, end mill, and ball nose cutters End mills (middle row in image) are those tools which have cutting teeth at one end, as well as on the sides. The words end mill are generally used to refer to flat bottomed cutters, but also include rounded cutters (referred to as ball nosed) and radiased cutters (referred to as bull nose, or torus). They are usually made from high speed steel (HSS) or carbide, and have one or more flutes. They are the most common tool used in a vertical mill.

Slot drill
Slot drills (top row in image) are generally two (occasionally three or four) fluted cutters that are designed to drill straight down into the material. This is possible because there is at least one tooth at the centre of the end face. They are so named for their use in cutting key way slots. The term slot drill is usually assumed to mean a two fluted, flat bottomed end mill if no other information is given. Two fluted end mills are usually slot drills, three fluted sometimes are not, and four fluted usually are not.

Roughing end mill

Roughing end mills quickly remove large amounts of material. This kind of end mill utilizes a wavy tooth form cut on the periphery. These wavy teeth form many successive cutting edges producing many small chips, resulting in a relatively rough surface finish. During cutting, multiple teeth are in contact with the workpiece reducing chatter and vibration. Rapid stock removal with heavy milling cuts is sometimes called hogging. Roughing end mills are also sometimes known as ripping cutters.

Ball nose cutter

Ball nose cutters (lower row in image) are similar to slot drills, but the end of the cutters arehemispherical. They are ideal for machining 3-dimensional contoured shapes in machining centres, for example in moulds and dies. They are sometimes called ball mills in shop-floor

slang, despite the fact that that term also has another meaning. They are also used to add a radius between perpendicular faces to reduce stress concentrations. There is also a term bull nose cutter, which refers more to a cutter having a corner radius less than half the cutter diameter; e.g. a 20 mm diameter cutter with a 1 mm radius corner.

Slab mill

HSS slab mill Slab mills are used either by themselves or in gang milling operations on manual horizontal or universal milling machines to machine large broad surfaces quickly. They have been superseded by the use of carbide-tipped face mills which are then used in vertical mills or machining centres.

Side-and-face cutter

Side and face cutter The side-and-face cutter is designed with cutting teeth on its side as well as its circumference. They are made in varying diameters and widths depending on the application. The teeth on

the side allow the cutter to make unbalanced cuts (cutting on one side only) without deflecting the cutter as would happen with a slitting saw or slot cutter (no side teeth). Cutters of this form factor were the earliest milling cutters developed. From the 1810s to at least the 1880s, they were the most common form of milling cutter, whereas today that distinction probably goes to end mills.

Involute gear cutter

Involute gear cutter number 4: 10 diametrical pitch cutter Cuts gears from 26 through to 34 teeth 14.5 degree pressure angle There are 8 cutters (excluding the rare half sizes) that will cut gears from 12 teeth through to a rack (infinite diameter).

Hob

Hobbing cutter

Aluminium Chromium Titanium Nitride (AlCrTiN) coated Hob using Cathodic arc deposition technique

These cutters are a type of form tool and are used in hobbing machines to generate gears. A cross section of the cutters tooth will generate the required shape on the workpiece, once set to the appropriate conditions (blank size). A hobbing machine is a specialised milling machine.

Face mill
Carbide tipped face mill A face mill consists of a cutter body (with the appropriate machine taper) that is designed to hold multiple disposable carbide or ceramic tips or inserts, often golden in color. The tips are not designed to be resharpened and are selected from a range of types that may be determined by various criteria, some of which may be: tip shape, cutting action required, material being cut. When the tips are blunt, they may be removed, rotated (indexed) and replaced to present a fresh, sharp face to the workpiece, this increases the life of the tip and thus their economical cutting life.

Fly cutter
A fly cutter is composed of a body into which one or two tool bits are inserted. As the entire unit rotates, the tool bits take broad, shallow facing cuts. Fly cutters are analogous to face mills in that their purpose is face milling and their individual cutters are replaceable. Face mills are more ideal in various respects (e.g., rigidity, indexability of inserts without disturbing effective cutter diameter or tool length offset, depth-of-cut capability), but tend to be expensive, whereas fly cutters are very inexpensive.

Woodruff cutter

Woodruff key cutters and keys Woodruff cutters are used to cut the keyway for a woodruff key.

Hollow mill
Hollow milling cutters, more often called simply hollow mills, are essentially "inside-out endmills". They are shaped like a piece of pipe (but with thicker walls), with their cutting edges on the inside surface. They are used on turret lathes and screw machines as an alternative to turning with a box tool, or on milling machines or drill presses to finish a cylindrical boss (such as a trunnion).

Dovetail cutter
A dovetail cutter is an endmill whose form leaves behind a dovetail slot.

Using a milling cutter

Chip formation
Although there are many different types of milling cutter, understanding chip formation is fundamental to the use of any of them. As the milling cutter rotates, the material to be cut is fed into it, and each tooth of the cutter cuts away small chip of material. Achieving the correct size of chip is of critical importance. The size of this chip depends on several variables.

y y y y

Surface cutting speed (Vc): This is the speed at which each tooth cuts through the material as the tool spins. This is measured either in metres per minute in metric countries, or surface feet per minute (SFM) in America. Typical values for cutting speed are 10m/min to 60m/min for some steels, and 100m/min and 600m/min for aluminum. This should not be confused with the feed rate. Spindle speed (S): This is the rotation speed of the tool, and is measured in revolutions per minute (rpm). Typical values are from hundreds of rpm, up to tens of thousands of rpm. Diameter of the tool (D): Feed per tooth (Fz): This is the distance the material is fed into the cutter as each tooth rotates. This value is the size of the deepest cut the tooth will make. Feed rate (F): This is the speed at which the material is fed into the cutter. Typical values are from 20mm/min to 5000mm/min. Depth of cut: This is how deep the tool is under the surface of the material being cut (not shown on the diagram). This will be the height of the chip produced. Typically, the depth of cut will be less than or equal to the diameter of the cutting tool.

Concept Mill 55

TECHNICAL:
420 x 125 mm Milling Table (LxW) 190/140/260 mm Travel (X/Y/Z) 150-3500 R/min Spindle Speed Range 0 - 2 m/min Rapid Traverse 0 - 2 m/min Feed Rate Programmable 8 station Automatic Tool Changer - optional Tool Turret Similar to ISO 30 Tool System 115/230v, 50/60 Hz Power Supply Machine Dimensions (LxDxH) 960 x 1000 x 980 mm 190kg with ATC Machine weight Interchangeable Control System Fanuc Siemens Heidenhain CAM Concept

Construction Safety equipment Optional 4th Axis Hardened guideways Central Lubrication Fully enclosed working area

Cast Iron Compliance with CE regulations CNC Programmable c/w 3 jaw chuck

Concept Turn 55

TECHNICAL:
Max turning diameter Centre height Distance between centre Swing over bed Swing over cross slide Travel X Z Spindle speed Spindle bore Constant surface speed Spindle motor Rapid traverse Feed Tool Turret Power supply Machine Dimensions (LxDxH) 52 mm 65 mm 280 mm 130 mm 60 mm 48 x 236 mm 100 - 4000 R/min 16 mm Programmable 0.75 kW ( 1 hp ) 2 m/min 0 - 2 m/min 8 station automatic tool changer 230 V 50/60 Hz 400 x 695 x 840 mm

85 kg Machine weight Interchangeable Control System Fanuc Siemens Heidenhain CAM Concept 2 axes slant bed lathe Industrial design Compliance with CE regulations Safety equipment Automatic reference point return Fully enclosed working area

CODES USED IN CNC PROGRAMING:

Words acceptable to the EMC Interpreter D F G H I Tool radius compensation Number Feed rate General function (see below) Tool length offset X-axis offset for arcs X offset in G87 canned cycle Y-axis offset for arcs and Y offset in G87 canned cycle K Z-axis offset for arcs and Z offset in G87 canned cycle L number of repetitions in canned cycles and key used in G10 M N P Q R Miscellaneous function (see below) Line number Dwell time with G4 and canned cycles Key used with G10 Q feed increment in G83 canned cycle R arc radius canned cycle plane

J K L

S T X Y Z

S spindle speed Tool selection X-axis of machine Y-axis of machine Z-axis of machine

G - Codes
G words alter the state of the machine so that it changes from cutting straight lines to cutting arcs. Other G words cause the interpretation of numbers as millimeters rather than inches. While still others set or remove tool length or diameter offsets. Most of the G words tend to be related to motion or set of motions.

M - Codes
M words are used to control many of the I/O functions of a machine. M words can start the spindle Andturn on mist or flood coolant. M words also signal the end of program or a stop within a program. The complete list of M words available to the RS274NGC programmer is included in the below table.

What is pipe vise?

A pipe vise is an apparatus which enables a pipe to be held tightly. Complete with two half-circle jaws, the pipe vise can be tightened to grip a pipe and hold it securely while it is being worked on. Often a feature of a common bench vise, the addition of a pipe vise makes the bench vise an all-purpose tool capable of performing many more tasks. The teeth of a pipe vise are critical in the gripping success of the tool, as rounded or dull teeth allow the pipe to slip and roll even though the pipe vise is tightened. Certain models of pipe vise contain a linked chain component that is used to grip and hold thepipe. By placing the chain around the pipe and securing it into position on the vise, it is tightened by the vise handle and provides the ultimate in clamping force. The chain's ability to wrap tightly around the pipe instead of simply contacting two sides makes it possible to grip the entire circumference of the pipe, more than quadrupling the clamping surface of the vise. Professional pipe workers and plumbers often have a pipe vise mounted on a tripod. This standalone vise is able to be located at any work site the pipe worker requires. By having the vise nearer to the actual work site, the worker saves valuable time by not having to return to a shop or work truck each time to clamp the pipe into a vise. This design also allows for the placement of the vice at any distance away from the work site, compensating for different lengths of pipe being used on the project. Some pipe vises used in welding are equipped with an electric motor. This style of vise allows the welder to rotate the pipe as it is being welded. By rotating the pipe, the welding bead is able to remain constant from start to finish without having any gaps or spaces in the bead. This rotational vise design is also available for pipe threaders. As the pipe is rotated in the vise, threads are actually rolled into the end of the pipe. The threads are installed in order to allow thread-on adapters, faucets and splices onto the pipe sections. In a manufacturing environment, the pipe vise is a critical component in the assembly of pipeline components. The vise is able to hold the section of pipe in place while an assembly line worker performs his task. Once the particular task is accomplished, the worker is able to release the pipe from the vise at his station and send it on its way to the next station.

Fig.1 pipe vice

How to install pipe vice?

The steps involved in the process to install a vice can vary depending on the type of vice you buy. Woodworking vises, for example, are usually installed on the front or side of a workbench, and the jaws of the vice will be lined up to be flush with the work surface. Other types of vises may be installed directly on the workbench top. Determine what kind of projects you will be doing most regularly and how you are likely to use the vice before you begin to install a vise on your workbench. Regardless of the type of vise you will be working with, be sure to install a vise in such a way that it will not work loose, even when placed under intense strain or under significant torque. Purchase the largest bolts you can find that will fit in the bolt holes built into the vice's base. Be sure to purchase plenty of washers to fit the bolt, as well as nuts that will secure the bolts in place. The bolts should be long enough to fit through the vise base plate as well as through the bench, and about two inches (5 cm) of the bolt should protrude through the other end of the bench.

The next step you will need to undertake to install a vise is drilling the holes for the bolts. Line up the vise in the position you want it to be secured, and double check your placement. This is especially important when installing a woodworking vise, as the jaws of the vise will need to be lined up flush with the top of the workbench. Many woodworkers will even line up the jaws of the vise so they are placed directly on a corner of the workbench, and the jaws are flush with the two sides of the bench as well. Mark the holes by making pencil markings within the bolt holes on the vise base plate. To install a vise properly, drill holes that match the size of the bolt holes as closely as possible. You can err a bit larger, but a bolt hole that is too small will not allow passage of the bolt through the workbench. Once the holes are drilled, place the vise in position and slide two washers onto the bolt before sliding that bolt through the hole. On the other side of the bench, where the bolt is protruding through, place two more washers and then a nut to secure each bolt in place. An engineer's vise, also known as a metalworking bench vise or fitter's vise, is used in metalworking applications. The jaws are made of soft or hard metal. The vise is bolted onto the top surface of the bench with the face of the fixed jaws just forward of the front edge of the bench. The bench height should be such that the top of the vise jaws is at or just below the elbow height of the user when standing upright. The vise may include other features such as a small anvil on the back of its body. The nut in which the screw turns may be split so that, by means of a lever, it can be removed from the screw and the screw and moveable jaw quickly slid into a suitable position at which point the nut is again closed onto the screw. The disadvantage to this system is lower precision, as compared to a solid screw system. Vise screws are usually either of an Acme thread form or a buttress thread. Those with a quick-release nut use a buttress thread. Some vises have a hydraulic or pneumatic screw, making setup not only faster, but more accurate as human error is reduced.[citation needed] For large parts, an array of regular machine vises may be set up to hold a part that is too long for one vise to hold. The vises' fixed jaws are aligned by means of a dial indicator so that there is a common reference plane. For multiple parts, several options exist, and all machine vise manufacturers have lines of vises available for high production work: The first step is a two clamp vise, where the fixed jaw is in the center of the vise and movable jaws ride on the same screw to the outside. The next step up is the modular vise. Modular vises can be arranged and bolted together in a grid, with no space between them. This allows the greatest density of vises on a given work surface. This style vise also comes in a two clamp variety.

The various parts of a pipe vice. To assemble the vice, thescrew rod 4 is screwed into the base 1 from above. When the circular groove at the end of thescrew rod is in-line with the 6 mm diameter transverse hole in the housing, the movable jaw 2 isinserted from below. After alignment, two set screws 3 are inserted into the jaw. This arrangementallows the jaw to move vertically without rotation when the handle is operated and the screw is turning. The V-shaped base of the housing can accommodate pipes of different diameters. The serrations provided on the V-shaped end of the movable jaw provide effective grip on the pipe surface. Tower vises are vertical vises used in horizontal machining centers. They have one vise per side, and come in single or dual clamping station varieties. A dual clamping tower vise, for example, will hold eight relatively large parts without the need for a tool change. Tombstone fixtures follow the same theory as a tower vise. Tombstones allow four surfaces of vises to be worked on one rotary table pallet. A tombstone is a large, accurate, hardened block of metal that is bolted to the CNC pallet. The surface of the tombstone has holes to accommodate modular vises across all four faces on a pallet that can rotate to expose those faces to the machine spindle. New work holding fixtures are becoming available for five-axis machining centers. These specialty vises allow the machine to work on surfaces that would normally be obscured when mounted in a traditional or tombstone vise setup.

USE:
Pipe vices are designed for holding pipes, to facilitate operations such as threading or cutting-off to required length.

CNC PROGRAM:

N10 G00 G17 G40 G54 G80 G90 G94 N20 T1 D1 N30 M03 S1000 N40 G00 Z50 N50 X-42 Y-43.5 N60 G01 Z-2 F500 N70 G01 X42 Y-43.5 N80 G01 X42 Y-38 N90 G03 X40 Y-36 U3 N100 G01 X26 Y-36 N110 G02 X24 Y-34 U4.5 N120 G01 X24 Y-15 N130 G03 X10 Y8 U26 N140 G02 X7.5 Y11.78 U4.5 N150 G01 X7.5 Y31.5 N160 G03 X4.5 Y34.5 U3 N170 G01 X-19.5 Y34.5 N180 G03 X-22.5 Y31.5 U3 N200 G01 X-22.5 Y3 N210 G03 X-18 Y-1.5 U4.5 N220 G01 X-7.5 Y-1.5 N230 G02 X6 Y-15 U13.5 N240 G02 X4.5 Y-19.5 U7.5

N250 G01 X-4.3180 Y-28.3180 N260 G02 X-10.6820 Y-28.3180 U4.5 N270 G01 X-18 Y-21 N280 G01 X-22 Y-21 N290 X-22 Y-31.5 N300 G02 X-27 Y-36 U4.5 N310 G01 X-40 Y-36 N320 G03 X-42 Y-38 U3 N330 G01 X-42 Y-43.5 N340 G00 Z5 N350 X-18 Y34.5 N360 G01 Z-2 F500 N370 G01 X-18 Y43.5 N380 G01 X0 Y43.5 N390 G01 X0 Y34.5 N400 G00 Z5 N410 X12.25 Y-19.75 N420 G01 Z-2 F500 N430 G01 X12.25 Y-12.25 N440 G02 X16.75 Y-12.25 U2.25 N450 G01 X16.75 Y-19.75 N460 G02 X12.25 Y-19.75 U2.25 N470 G00 Z50 N480 M30

BIBILOGRAPHY:
y y y y Production Technology R.K.Jain CNC machines D.S. Pable CNC machines M. Adiphan CAD/CAM theory & practice IbrahinLeid

CONCLUSION:
Computer Numerical Control (CNC) technology plays a vital role in the overall improvement of plants productivity. The component when manufactured by the conventional machining process shall not have smooth surface finish and has no accuracy in dimension and has low repeatability. Whereas when manufactured in Computer Numerical Control machine gives a perfect component of greater accuracy in helps in complete machining process. By the conventional means the time taken for the manufacturing a single component is much higher than that manufacturing through.

 The tool path movement where checked by stimulation test an inherent features of CNC machines, prior to actual machining.  Thus avoiding manufacturing unnecessary machine elements.  The desired machine elements were machined in accordance.  Thus with its rich blend of various advantages CNC stands a top in modern machining techniques.