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Farmingdale State College
School of Engineering Technologies
ADVANCED
MACHINE TOOL LABORATORY
MANUAL & PROJECTS
PREPARED BY:
Prof. Dimitrios Maltezos, P.E. Mechanical/Manufacturing Department SUNY College of Technology
Revised by students of Prof. Maltezos Matthew J. McLaughlin & Steven Ellinghaus May, 2005
Edition 3. 2 May 2007
Table of Contents
Chapter 1 - Introduction
Required Items
- Text: Kibbe, R.R., Machine Tool Practices, 5th^ ed.
- Safety Glasses (with plastic lenses; Titanium Frames)
- Clean white apron or lab coat
- 6” scale
- Loose-leaf notebook, standard 8½ x 11”
- 2” wide inexpensive paint brush
NOTE: Students without the required items will not be allowed to attend laboratory classes. Most items can be purchased at the student bookstore.
Text Required Reading Assignments
Week Section Pages Topic 1 Milling Machines and Accessories / Maintenance 2 Milling Cutters 3 Cutting Speeds, Feeds, and Depth of Cut 4 Introduction to CNC 5 CNC Programming 6 COMPUMILL 2500 3-Axis CNC Milling Operations 7 Milling Machine Setups, Milling Operations 8 Mid term exam 9 Indexing, Dividing Head 10 Gear Cutting 11 Special Milling Operations 12 Gear Shaper and Surface Grinder 13 Introduction to Omniturn CNC Turning Center 14 MasterCam Software 15 FINAL EXAM
NOTE: The above required reading is a minimum. Additional reading would be assigned during lectures.
Required Projects
- Mill two (2) aluminum plates to size using the Bridgeport vertical milling machine.
- Machine an aluminum block using hand-controlled vertical milling machine.
- Machine aluminum plate with student's initials using CNC milling machine.
- Machine aluminum plate with the number 43 using CNC milling machine.
- Pocket milling of an aluminum plate using CNC milling machine.
- Machine aluminum plate (open assignment) using CNC milling machine.
- Cut a spur gear with indexing head, using the Cincinnati Universal milling machine.
- Cut a spur gear using gear shaper.
- Grinding a parallel surface.
- Turn several diameters and lengths on an aluminum shaft, using Omni CNC Lathe Machine.
Special Instructions
Each student is responsible for his or her projects. All projects shall be first drawn on an 8 ½ x 11 inch (size A) paper using either AutoCAD or by hand. At the completion of each project, the student will submit his/her project to the instructor for evaluation and grading. In order to emphasize the engineering aspects of the course, a typed report containing the following items is also required to be submitted by the student at the same time:
- Drawing
- Sheet with calculations such as RPM, feed, machining time
- Numerical control program (G codes, if any)
- Route Sheet
See sample reports for details and report format.
M05 Spindle stop M06 Rapid to tool change, spindle off and stop
X, Y, Z, I and J Codes X X motion dimension Y Y motion dimension Z Z motion dimension I X arc center for circular mill (absolute) J Y arc center for circular mill (absolute)
Tool Code and Feedrate Tn Tool number Fn Feedrate number (IPM)
N, G, X, Y, Z, I, J, and F codes may appear together in one line. N, M, and T codes may appear together in one line.
Compumill Instructions
NOTE: This is a quick list of basic setup procedures for the Compumill. Please refer to the Compumill handout for more detailed instruction.
Step 1. Turn Machine On.
- Main power switch at right rear of machine.
- Control switch at right side of the CNC control.
- Correct any fault status errors if any, then press Reset Button twice.
Step 2. Reference Machine.
- Select Mode Select = > Select 0 (Jog Mode) = > Select a speed = > Use X,Y,Z Jog switches to move table stops close to micro switches (2" approximately)
- Select R (Reference zero) = > Turn X,Y,Z Jog switch in (+) direction X, Y first then Z.
Step 3. Go to home position.
- Select H (Home) = > Turn X,Y,Z Jog switches to (+) direction.
Step 4. Set Part Zero. (X and Y only)
- Load Work in fixture = > Load indicator in spindle.
- Use Mode Select and Select R (for Reference).
- Select a speed = > Use X,Y,Z Jog switches to move in (-) direction, until indicator in spindle aligned with part zero (0,0) Coordinates.
- Select 9 (Zero Set) = > Turn X,Y Jog switches in (+) direction.
- Select H (Home) = > Turn X,Y,Z Jog switches to (+) direction.
Step 5. Calibrate all necessary tools.
- Load tool #1 in spindle.
- Select a speed = > Use X,Y,Z Jog switches to move tool to surface of work using paper as a feeler. Spindle On.
- Select Mode Select = > Select 6 (Tool Tables) = > Select T (Tool length/Cutter diameter) = > Push soft key Tool Calibrate.
- Select Mode Select => Select 0 (Jog Mode) => Select H (Home) = > Turn X,Y,Z Jog switches to (+) direction. Z axis First.
Repeat Steps if other tools are required. NOTE: Make sure proper tool number is highlighted in tool length/cutter diameter menu. If not, just type in T and number of tool to be calibrated then hit Enter key.
Step 6. Load Program.
- Select Mode Select = > Select 9 (Load Program) = > Push Soft key Load Program. NOTE: Screen should display busy loading.
- On computer Select 6 (Setup) = > Select A or B for drive being used = > Select 1 (Select program) = > Choose number of program to be loaded Select 2 (Load Program) = > Hit space bar
Step 7. Run Graphics.
- Select Mode Select = Select G (Graphics) = > Select Reset = > Push Green Cycle Start button. NOTE: The Cycle Start button may have to be pushed more than once.
Run Program.
- Select Mode Select = > Select 1 (Auto) = > Select Reset = > Push soft key View Graph = > Push Green Cycle Start button = > Load - first tool => Push Blue Tool Change Cycle Start button on front panel = > Set Spindle speed = > Push Green Cycle Start button.
To select from loaded programs:
- Select Mode Select > Select C for Catalog
- Type selected program and enter (Program is highlighted)
- Select Mode Select > Run Graphics "G".
- Select Mode Select P4 to check Z coordinates.
- Select Mode Select 1 for Auto
Incremental Mode – Linear And Circular Mill And Drill.
The drawing below is symmetric about the x and y axes
LINE
END
Example of student’s initials. Project modeled in Inventor. (Program is listed on next page)
Example Project
- Chapter 1 - Introduction
- Required Items
- Text Required Reading Assignments
- Required Projects
- Special Instructions
- Chapter 2 - Computer Numerical Control - CNC
- Introduction
- Quick Reference Instructions
- Compumill Instructions
- Sample Part Program
- Sample Part Program
- Pocket, Frame and Circle Milling for Dynapath Delta 20 Controller
- New Britain Machine Controller SC-M4000
- General Information
- Codes honored by the controller
- OmniTurn CNC Lathe
- Codes Honored by the OmniTurn Control
- Chapter 3 - Gears
- Gear Types
- Indexing Head
- Spur Gear Terminology
- High Speed Gear Shaper
- Setup procedure for shaping external spur gears
- Change Gear Chart
- Checking external spur gear sizes
- Fellows Gear Shaper
- Bonus Projects
- Sample Part Program
- N0100 G NO. PROGRAM DATA COMMENTS
- N0110 G
- N0120 T1M
- N0130 M
- N0140 M
- N0150 G00X.750Y-.
- N0160 G01Z.100F
- N0170 Z-.050F
- N0190 Y. N0180 G91 INCREMENTAL MODE
- N0200 G03X-1.5I-.750J
- N0210 G01Y-.
- N0220 G03X1.500I.750J
- N0230 G01Y.
- N0240 Z.150F
- N0250 G00Y1.
- N0260 G01Z-.150F
- N0270 X1.500Y-2.
- N0280 Z.150F
- N0290 T2M
- N0300 M
- N0310 M
- N0320 G
- N0330 G81X-1.5Y1.000Z-.100R.100F
- N0340 G91X3.
- N0350 Y-2.
- N0360 X-3.
- N0370 G
- N0380 M - T1 - .250 END MILL. TOOLS DEPTHS - T2 - .250 DRILL.
- N010G
- N020G
- N030M
- N040T
- N050M
- N060M
- N070G00X3.212Y2.
- N080G01Z.1F
- N090G01Z-.05F
- N100G01X2.
- N110G03X2.712Y1.5I2.712J2.
- N111G01X2.712Y1.
- N120G03X2.712Y.350I2.712J.
- N125G01X2.712Y.
- N130G01X3.
- N140G01Z.1F
- N150G00X.350Y.
- N160G01Z.1F
- N170G01Z-.05F
- N180G01X1.419Y2.
- N190G03X.766Y2.078I1.100J2.
- N195G01X.766Y2.
- N200G01X1.495Y1.
- N210G02X.607Y.766I1.1J.
- N250G01X.607Y.
- N260G01Z.1F
- N270G00X.350Y1.
- N280G01Z.1F
- N290G01Z-.05F
- N300G01X.
- N310G01Z.1F
- N320G00X1.62Y1.
- N330G01Z.1F
- N340G01Z-.05F
- N350G01X1.
- N360G01Z.1F
- N370G00X3.044Y1.
- N380G01Z.1F
- N390G01Z-.05F
- N400G01X3.
- N410Z.1F
- N420M
- Example Project
- Example Project
- Example Route Sheet
Required Project
Pocket, Frame and Circle Milling for Dynapath Delta 20 Controller
Introduction
Pocket (G0): removing all the material inside an arbitrarily designated area to a specified depth. The shape can be irregular or regular. (Event type 3.)
Frame (G7): removing material as wide as the tool. As in pocket milling, the shape can be irregular or regular.
Circle: It is possible to mill a circle as either a frame or pocket. (Event type 4.)
