CNC MachiningPittsburg State University Technology Education

AUTOMATED SYSTEMSName: VIGNESH K VELUSAMY Date: 5/1/2023

PROJECT OVERVIEW

The project is to learn about the Automated Systems in a brief context. Among different automated technologies that exist in an industrial platform, CNC program is one of the basic and widely used Automated Programming System. In this project, programmed numerical control codes in Absolute, Incremental and polar types, to machine a block of wood in a CNC PRO Light 1000 Milling machine. General machining operations like facing, pocketing, holes are made using different types of programming. Practiced the setup procedure before to starting the machining process and learned the safety measures during the operation.

ACTIVITY 1:

G-CODE PROGRAMMING

; Vignesh K Velusamy; Tooling: 0.250; Work piece: T 0.750 W 1.970 L 3.980; Slot: W 0.346 L 2.212 D 0.202; Absolute Programming; Activity #1; Slot Milling; Pass 1N10G90N15M3N20G0X0Y0 N30Z.1N40X1.055Y.937N60Z-.302N70X2.93N80Y1.03N90X1.055N100Y.937N100Z.302N110M5N120G0X0Y0

; Vignesh K Velusamy; Tooling: 0.250; Work piece: T 0.750 W 1.970 L 3.980; Slot: W 0.346 L 2.212 D 0.202; Absolute Programming; Activity #1; Slot Milling; Pass 2N10G90N15M3N20G0X0Y0 N30Z.1N40X1.055Y.937N60Z-.202N70X2.93N80Y1.03N90X1.055N100Y.937N100Z.302N110M5N120G0X0Y0

EQUIPMENT SET-UP

Equipment name is CNC Base for 1000 Prolight.Setup:

Make sure the machine works fine, check the fuses and safety switches. Place the Part onto the machining table and clamp the smaller part with spacers, the part should not touch the base. Use vice for the larger part, tighten the jaws so that the part stay put. Insert the Tool using the adapter and make sure it fits well onto the spindle. Set the Tool to the origin of the part block either using the manual jog control or using the computer program for the CNC

base for 1000 Prolight software.

MACHINING THE PART

Before machining the part, some setting needs to be adjusted and entered in the software program to get the part machined correctly. The following procedure explain the Pre- and Post-machining process;

Performance Performance

Start the program, and open new program to enter the codes. From the Settings tab, select verify setting, and enter the work piece size (Dimensions in IN). Move the tool bit suing the computer controller to the find the edges for the X, Y and Z axis. Make sure the tool is set at 90o angle to the respective sides before setting the zero position, use a thin sheet of paper to find

the tool touches the part by continuously moving the paper. Once the X, Y and Z set to zero, move the tool half the bit size from the X and Y positions to set the Origin Position. After setting the origin the Equipment is ready to run the program to machine the part, but before checking the program runs

correct is recommended. From Program tab, select verify option to see the simulation run each code virtually to check the program is correct or not. Finally Run the program and machine the part, use the emergency stop in the machine or from computer or pressing SPACE

BAR in PC keyboard to halt the process. Use Vacuum to remove the dust and other scrap material from the work piece and the Equipment. Wear Protective Glasses once entered the Machine Shop.

FINISHED PART

The completed part is a piece of stock with centered slot.

Fig. Pass 1.1Fig. Pass 1.2

Lessons Learned:

Form this exercise, learned how to do CNC programming in Absoulte programming type. Familiarized with Numerial Control Codes and their usage in different machining environment. Practiced to setup the Eqiupment for Pre- and Post- Machining and the procedures to do it. Operated the equipmet, CNC Base for ProLight software program to mancine the Part.

ACTIVITY 2:

G-CODE PROGRAMMING

; Vignesh K Velusamy; Tooling: 0.250; Work piece: T 0.750 W4.00 L 6.50; Absolute Programming; Activity #2N10G90N20M3N30G0X0Y0 Z.1N40X.375Y.375N60Z-.745N70Y1.55N80X.823Y2.00N90X.375Y2.45N100Y2.875N110X1.130Y3.625N120X2.875N130Y3.250N140X3.0Y3.125N150X4.00

N160X4.125Y3.250N170Y3.625N180X5.302N190X6.125Y2.802N200Y1.750N210X4.750Y.375N220X3.375N230Y.875N240X2.125N250Y.375N260X.375N265Z.1N270M5N280G0X0Y0

EQUIPMENT SET-UPEquipment name is CNC Base for 1000 Prolight.Setup:

Make sure the machine works fine, check the fuses and safety switches. Place the Part onto the machining table and clamp the smaller part with spacers, the part should not touch the base. Use vice for the larger part, tighten the jaws so that the part stay put. Insert the Tool using the adapter and make sure it fits well onto the spindle. Set the Tool to the origin of the part block either using the manual jog control or using the computer program for the CNC

base for 1000 Prolight software.

FINISHED PARTThe Computer simulation showing the part with Milling profile .

Fig. 2.1 Absolute programming of Milling profile ACTIVITY 3:

G-CODE PROGRAMMING

; Vignesh K Velusamy; Tooling: 0.250; Work piece: T 0.750 W 4.5 L 6.50; Incremental Programming; Activity #3N10G91N20M3N30G0X0Y0Z.1N40X.375Y.375N60Z-.845N70Y3.750N80X2.250N90Y-.750N100X1.570N110X.680Y.680

N120Y1.070N130X2.250N140Y-3.650N150X-.550Y-1.100N160X-2.130N170X-.450Y.450N180X-.450Y-.450N190X-3.18N200Z.950N210M5N220G0X0Y0

EQUIPMENT SET-UPEquipment name is CNC Base for 1000 Prolight.Setup:

Make sure the machine works fine, check the fuses and safety switches. Place the Part onto the machining table and clamp the smaller part with spacers, the part should not touch the base. Use vice for the larger part, tighten the jaws so that the part stay put. Insert the Tool using the adapter and make sure it fits well onto the spindle. Set the Tool to the origin of the part block either using the manual jog control or using the computer program for the CNC

base for 1000 Prolight software.

FINISHED PARTThe Computer simulation showing the part with Milling profile .

Fig. 3.1 Incremental Programming of milling profile

POLAR G-CODE PROGRAMMING AND ABSOLUTE PROGRAMMING

; Vignesh K Velusamy; Tooling: 0.250”; Work piece: T 0.750 W5 L 5; Holes; Inside dia: .25” depth: .625”; Outside dia: .25” depth: .375”; Finished part: 4 x 4; Holes circle radius: 1.25”; Offset Depth: 3/16” or Depth of cut: 0.576”; Using Polar and Absolute type N10G90N15M3N20G0X0Y0Z.1N25Z-.625N30Z.1N35G16N40G99G81X1.25R.125Y0Z-.375N50X1.25Y45N60X1.25Y90N70X1.25Y135N80X1.25Y180N90X1.25Y225

N100X1.25Y270N120X1.25Y315N140G15G80N150G90N160G0X0Y0Z.1N170X-2.125Y-2.125N180Z-.25N190Y2.125N200X2.125N210Y-2.125N220X-2.125N180Z-.5N190Y2.125N200X2.125N210Y-2.125N220X-2.125N180Z-.0625N190Y2.125N200X2.125N210Y-2.125N220X-2.125N300Z.1

N310M5N320G0X0Y0

EQUIPMENT SET-UPEquipment name is CNC Base for 1000 Prolight.Setup:

Make sure the machine works fine, check the fuses and safety switches. Place the Part onto the machining table and clamp the smaller part with spacers, the part should not touch the base. Use vice for the larger part, tighten the jaws so that the part stay put. Insert the Tool using the adapter and make sure it fits well onto the spindle. Set the Tool to the origin of the part block either using the manual jog control or using the computer program for the CNC

base for 1000 Prolight software.

MACHINING THE PARTBefore machining the part, some setting needs to be adjusted and entered in the software program to get the part machined correctly. The following procedure explain the Pre- and Post-machining process;

Start the program, and open new program to enter the codes. From the Settings tab, select verify setting, and enter the work piece size (Dimensions in IN). Move the tool bit suing the computer controller to the find the center for the X, Y and Z axis. Make sure the tool is set at 90o angle to the respective sides before setting the zero position, use a thin sheet of paper to find

whether the tool touches the part by continuously moving the paper. Once the X, Y and Z set to zero, move the tool half the size of the Part from the X and Y positions to set the Origin Position. After setting the origin the Equipment is ready to run the program to machine the part, but before checking the program runs

correct is recommended. From Program tab, select verify option to see the simulation run each code virtually to check the program is correct or not. Finally Run the program and machine the part. Start from center by drilling the holes first and then move on to milling, where give three passes each not more than ¼” depth

of cut. Use the emergency stop in the machine or from computer or pressing SPACE BAR in PC keyboard to STOP the process. Use Vacuum to remove the dust and other scrap material from the work piece and from the Equipment. Wear Protective Glasses once entered the Machine Shop.

FINISHED PARTThe Computer simulation showing the part with Milling profile.

Fig. 4.1 Finished

Lessons Learned:

Form this exercise, learned how to do CNC Polar Programming in Absoulte programming type. Familiarized with Numerial Control Codes and their usage in radial machining environment. Practiced to setup the Eqiupment for Pre- and Post- Machining and the procedures to do it. Operated the equipmet, CNC Base for ProLight software program to mancine the Part.

CNC ROUTER PROGRAMMING:

Machine: AXYZ CNC ROUTERMaterial: MDFGame: Marble RacerMachine Set up:

Turn on the AXYZ CNC router, let it to heat up the cutting head. Place the MDF board on the table, use fixture to secure in one place. Turn on the suction clamp and place the cutting tool in the spindle. Set origin using F3 function; set surface height, bottom height and top reach height using F84 function. Use F8 function to set surface height alone. Start machining using F9 function.

Procedure: File Setting Use TOOLPATH Software to load the machining file onto the AXYZ machine. Load the marble racer file “. DFX” file format. Using Layout menu set the origin, size and orientation. Using Analysis menu to Group the color for the shapes, BLUE – outside, GREEN – Open, RED - inside. Setup menu is used to choose the depth of cut and for the multi-pass option Once file is setup press SEND button and then press Transfer button to upload the file into CNC. Turn off the machine and suction clamp and dust suction after machining.

Finished:

Fig. 5.1 Finished Marble Racer Game

GORILA GAME DESIGN PROJECT

Concepts Presented: AGGRAVATION BOARD GAME

Fig. 6.1 Proposed Concept

CAD File:Designed the layout for CNC router using SOLIDWORKS software.

Fig. 6.2 Solid works CAD file

Fig. 6.3 TOOLPATH file for CNC

Fig 6.4 Prototype for the Game Board

Procedure: CNC router machining

Took three pieces of Maple wood; shaped and glued together into 14” x 16” rectangular board. Developed the CAD file for the CNC Milling and CorelDraw file for Laser Engraving. Converted the CAD file into PLT Plotter format Imported the file into TOOLPATH software for CNC router. Using Analysis option selected the line to be Green and Holes to the Blue as a center marks, Two separate files for the center hole drilling using 0.5” round cutter head. And the outer – line is mill out with 1/8” milling head, with multi-pass 0.25” depth.

CNC table setup:

Place the 13”x16” board on the CNC table, then turned on the AXYZ router machine to heat the cutter head first.

Uploaded the files to the CNC, then turned on the suction clamping and the dust suction while operation. Using F3 option to set the Origin of the board, then F84 option to set the Surface height, Bottom depth

height and the Top reach height. F9 to start the program uploaded from the TOOLPATH software. Use Emergency stop in case of trouble, release the stop to start again. After drilling the holes, changed the cutting tool and adjusted the surface height with F8 option, rest

options remain same. After milling out the line, the board is cleaned and prepared for engraving.

Fig. 6.5 Milling operation done on the wood in AXYZ CNC router

Procedure: Engraving

Board is placed in the laser machine, set the reference and align the board using laser pointer. CorelDraw file is imported and placed on the sheet according to laser machine reference points. The design is sent to the VSNL 2.0 Pinter, properties for printing is adjusted. All lines are set to hairline and other shapes to 1 pt., in Black color. In Properties, material is Maple wood, in rast option; power is full, Speed is full and Rast percentage is

20% are chosen. Start the engraving by pressing start green button in the machine or on the software. Once finished engraving, using sand paper scrap of the burning mark and clean with vacuum.

CorelDraw Working setup:

Fig. 6.6 CorelDraw file for Engraving – front side

Fig. 6.7 CorelDraw file for Engraving – back side

Fig. 6.8 Laser Engraving file.

Finished Design:

Fig. 6.9 Finished Game design – front side Fig. 6.8 Finished Game design – back side

Fig. 6.10 Marble Board game ready to play