Mechanical Engineering

Department; Thapar
University

Manufacturing Processes
UT026
 Introduction to manufacturing processes

 Introduction to computer numerical control (CNC)

machines

 G and M code programming for simple turning

and milling operations

 introduction of canned cycles

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 Mechanical Engineering
Department; Thapar
University Manufacturing

All of the above products are produced by a combination of various processes called
MANUFACTURING
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 Mechanical Engineering
Department; Thapar
University Products & No. of Parts

Single material products Multi material (parts) products 12,000 parts

>15,000 parts >6 million parts

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Mechanical Engineering
Department; Thapar
University What is Manufacturing?

• Manufacturing is derived from the Latin:

manus= hand, factus=made

• Manufacturing in its broadest sense, is the

process of converting raw materials into
products.

• Manufacturing is the use of machines,

tools and labour to produce goods for use on
a larger scale.

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Mechanical Engineering
Department; Thapar
University Manufacturing as a Technical Process

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Mechanical Engineering
Department; Thapar
University Selecting Manufacturing Processes

 There is more than one method of manufacturing a part

from a given material,
 These transform a work material from one state of
completion to a more advanced state,
 Such as
 Change the geometry
 Change properties or appearance of the starting material
 Selection of particular machining processes depends not
only on the shapes to be produced by also on many factors
regarding material properties
 Brittle and hard material can not be shaped easily

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 Mechanical Engineering
Department; Thapar
University Selecting Manufacturing Processes

Machining
 Excess material removed from the starting piece so what
remains is the desired geometry
– Examples: turning, drilling, and milling; also grinding
and non-traditional processes

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 Mechanical Engineering
Department; Thapar
University Selecting Manufacturing Processes

Casting
 Starting material is heated sufficiently to transform it into a
liquid or highly plastic state
– Examples: metal casting, plastic moulding

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 Mechanical Engineering
Department; Thapar
University Selecting Manufacturing Processes

Forming and shaping

 Starting material is shaped by application of forces that
exceed the yield strength of the material
– Examples: (a) Forging, (b) extrusion

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 Mechanical Engineering
Department; Thapar
University Selecting Manufacturing Processes

Joining
 These operations join two or more components to create a
new entity
– Examples: (a) welding, (b) brazing, soldering

(a) (b)

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Mechanical Engineering
Department; Thapar
University

Machining Processes

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 Mechanical Engineering
Department; Thapar
University Machining Processes
Machine Tool Use for Machining

Lathe Milling Machine

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Mechanical Engineering
Department; Thapar
University Machine Tool Use for Machining

Shaping Machine Drilling Machine

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Mechanical Engineering
Department; Thapar
University Lathe

Components of Lathe
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 Mechanical Engineering
Department; Thapar
Various Operations That Can Be Performed in Lathe
University
– External

Turning Facing
 Turning tool moves axially,  Turning tool moves radially,
along the side of the along the end of the
workpiece workpiece
 removing material to form  removing a thin layer of
steps, tapers, chamfers, and material to provide a smooth
contours. flat surface

Straight turning Facing

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 Mechanical Engineering
Department; Thapar
Various Operations That Can Be Performed in Lathe
University
– External
Grooving Cut-off (parting) –
 Grooving tool moves radially,  Similar to grooving, cut-off tool
into the side of the moves radially, into the side of the
workpiece, workpiece,
 cutting a groove equal in  continues until the centre or inner
width to the cutting tool. diameter of the workpiece is
reached.

Grooving Cut-off (Parting)

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 Mechanical Engineering
Department; Thapar
Various Operations That Can Be Performed in Lathe
University
– External

Thread cutting
Threading tool, typically with a
60° pointed nose, moves axially,
along the side of the workpiece,

cutting threads into the outer

surface.

Thread cutting

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 Mechanical Engineering
Department; Thapar
Various Operations That Can Be Performed in Lathe
University
– Internal
Drilling Reaming
 A drill enters the workpiece  A reamer enters the workpiece
axially through the end, axially through the end
 Cuts a hole with a diameter  Enlarges an existing hole to the
equal to that of the tool. diameter of the tool.
 Performed after drilling to obtain
both a more accurate diameter and
a smoother internal finish

Twist drill
Reaming tool

Feed direction
Feed direction

Drilling Reaming

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Mechanical Engineering
Department; Thapar
Various Operations That Can Be Performed in Lathe
University
– Internal
Boring Tapping
 A boring tool enters the workpiece  A tap enters the workpiece axially
axially, through the end
 Cuts along an internal surface to  Cuts internal threads into an
form different features, such as existing hole.
steps, tapers, chamfers, and  The existing hole is typically drilled
contours. by the required tap drill size that
 Enlarge the existing hole. will accommodate the desired tap.

Boring tool

Tapping tool

Feed direction Feed direction

Boring Tapping

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Mechanical Engineering
Department; Thapar
University

Computer Numerical Control (CNC) Machine

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 Mechanical Engineering
Department; Thapar
University Computer Numerical Control (CNC)

 The functions of machine tool are partly or fully taken over by a

dedicated computer (i.e computer controlled),
 A micro or minicomputer is assigned with machine tool,
 The movements of machine components is controlled by coded
instructions in the form of numbers or letters (i.e program),
 The program may be prepared by programmer or obtained from
drafting software (i.e Autocad),
 The programs can be modified and displayed at the machine, along
with a simulated view of the process,
 Availability of small computer with large memory and program editing
capabilities popular the use of CNC systems widely.

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Mechanical Engineering
Department; Thapar
University
Computer Numerical Control (CNC) Machine

Lathe Milling machine

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 Mechanical Engineering
Department; Thapar
University
CNC Lathe – G Code

 G-code is the most widely used as numerical control (NC)

programming language
 Generally it is telling the computerized machine tools what type of
action to perform or how to make something
 Such as:
 Where to move the cutting tool
 How fast to move the cutting tool
 Which path the cutting tool will move
 Within a machine tool, a cutting tool is moved according to the
instructions of G-code through a toolpath and cuts away
material to leave only the finished workpiece.

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 Mechanical Engineering
Department; Thapar
University
CNC Lathe – G Code

 G00 – Rapid transverse (or, Rapid movement)

 G01 – Linear motion with feed
 G02 – Tool movement in clock wise direction
 G03 - Tool movement in anti-clock wise direction
 G04 – Dwell time (or, waiting time)
 G17 – XY plane
 G20 – Inches mode
 G21 – Metric mode (in mm)
 G28 – Go to machine home position in incremental mode
 G98 – Feed in mm/min
 G99 – Feed in mm/rev
 U – Incremental mode in X- axis
 W – Incremental mode in Z- axis
 X – Absolute mode in X- axis
 Z - Absolute mode in Z- axis

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Mechanical Engineering
Department; Thapar
University
CNC Lathe – M Code

 M-code is used for Machine function / Auxiliary

function
 Such as:
 Rotation of spindle
 Tool change
 Program on or off

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 Mechanical Engineering
Department; Thapar
University
CNC Lathe – M Code

M00 – Programme stop

M02 – Program end. halts program execution. To execute the program once
again, the system must reset.
M03 – Spindle rotation clockwise
M04 – Spindle rotation anti-clockwise
M05 – Spindle stop
M06 – Tool change
M08 – Coolant on
M09 – Coolant off
M30 - Program Stop and Rewind. This command is used to stop the spindle, turns
the coolant off, terminates and reset the CNC program
M98 – Sub program calling
M99 – Sub program end

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 Mechanical Engineering
Department; Thapar
University
Workpiece zero points or Program zero point

 On CNC machines, tool traverses are controlled by coordinating systems.

 Their accurate position within the machine tool is established by “Zero Points”.
 The position the workpiece zero point can be freely chosen by the programmer
with in the workpiece
 The workpiece zero point should be placed along the spindle axis (center
line), in line with the finished contour.

Chuck Workpiece Zero point

X (+)

(0,0) Z (+)

Length of Workpiece

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 Mechanical Engineering
Department; Thapar
University G00 – Rapid transverse (or, Rapid movement)
Chuck Workpiece Tool
Syntax: Dia of w/p

G00 X_ Z_ X (+)

X= Co-ordinate in X-axis (0,0) Z (+)

Z= Co-ordinate in Z-axis

Length of Workpiece

Tool
Example: ϕ 25
G21 G98
2
G28 U0 W0 / Send tool to home position
M06 T0101 / Call tool no. 1
(0,0)
M03 S2500 / Rotate tool at a speed of 2500 rpm
G00 X25 Z2 / The position of tool
Position of tool
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 Mechanical Engineering
Department; Thapar
University G01 – Linear Motion with Feed
Syntax:
G01 X_ Z_ F_
Tool will come to the
X= Co-ordinate in X-axis
position at a feed rate
Z= Co-ordinate in Z-axis
F= Feed in mm/min ϕ 25 Tool
Example:
2
G21 G98
G28 U0 W0 / Go tool to home position (0,0)
M06 T0101 / Call tool no. 1
M03 S2500 / Rotate tool at a speed of 2500 rpm 30 X (+)
G00 X25 Z2 / First position of tool
ϕ 25 ϕ 24
G01 X24 F60 Z (+)
G01 Z -10 F60 / Final position of tool
after removing material

20 10
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 Mechanical Engineering
Department; Thapar
University G02 – Tool movement in clock wise direction
Syntax: Example:
G21 G98
G02 X_ Z_ R_ F_
G28 U0 W0 / Go to tool home position
X= Co-ordinate in X-axis M06 T0101 / Call tool no. 1
Z= Co-ordinate in Z-axis M03 S2500 / Rotate tool at a speed of 2500 rpm

R= Radius of curve G00 X16 Z0 / First position of tool

G02 X24 Z -4 R4 F60 / Final position of tool

ϕ 24

X (+)

R4
Z (+)

ϕ 16

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 Mechanical Engineering
Department; Thapar
University G03 – Tool movement in anti-clock wise direction
Syntax: Example:
G21 G98
G03 X_ Z_ R_ F_
G28 U0 W0 / Go to tool home position
X= Co-ordinate in X-axis M06 T0101 / Call tool no. 1
Z= Co-ordinate in Z-axis M03 S2500 / Rotate tool at a speed of 2500 rpm

R= Radius of curve G00 X8 Z0 / First position of tool

G03 X24 Z -8 R8 F60 / Final position of tool
G00 X 24 Z2
ϕ 24
G28 U0 W0 /Makes the tool to go to home position
X (+) M05 /Spindle stop
R8 M30 /Program reset
Z (+)
ϕ8

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Mechanical Engineering
Department; Thapar
University
Practice

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Mechanical Engineering
Department; Thapar
University
Practice
G21 G98 ------ Initial Settings
G28 U0 W0 ------ Going to home position
M06 T1 ------ Tool Change Position No. 01
M03 S1500 ------ Spindle clockwise with 1500 RPM
G00 X32 Z5 ------ Tool Moving to Tool Entry Point of X32 Z5 at Rapid Traverse
G01 X31 F80 ------ Giving First depth of cut of 0.5 mm at a feed rate of
80 mm / min
G01 Z-25 ------ Moving the tool towards Z-25 mm
G01 X32 ------ Retract the tool in X axis
G00 Z5 ------ Moving the tool to Z5 position
G01 X30 F80 ------ Giving Second depth of cut of 0.5 mm at a feed rate of
80 mm / min
G01 Z-25 ------ Moving the tool towards Z-25 mm
G01 X32 ------ Retract the tool in X axis
G00 Z5 ------ Moving the tool to Z5 position
G01 X29 F80 ------ Giving Third depth of cut of 0.5 mm at a feed rate of
80 mm / min
G01 Z-25 ------ Moving the tool towards Z-25 mm
G01 X32 ------ Retract the tool in X axis
G00 Z5 ------ Moving the tool to Z5 position
G01 X28 F80 ------ Giving Fourth depth of cut of 0.5 mm at a feed rate of
80 mm / min
G01 Z-25 ------ Moving the tool towards Z-25 mm
G01 X32 ------ Retract the tool in X axis
G00 Z5 ------ Moving the tool to Z5 position
G28 U0 W0 ------ Going to home position
M05 ------ Stop the spindle
M30 --------Program stop and rewind

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 Mechanical Engineering
Department; Thapar
University G94 – Facing Cycle
Syntax:
This cycle is used for stock removal in
G94 X_ Z_ F_
parallel tool path
X= Diameter to which movement is being
1. Rapid to Z position
made 2. Feed to X position
Z= Co-ordinate in Z-axis 3. Feed to start Z position
F= Feed 4. Rapid to start X position
Example:

G21 G98 ϕ 25 Tool

G28 U0 W0
X (+)
M06 T0101

M03 S2500
Z (+)
G00 X26 Z2

G94 X0 Z -0.5 F60 / Final position of tool

2
Z-1

Z-1.5

Z-2

G28 U0 W0
 Mechanical Engineering
Department; Thapar
University G90 – Straight Turning Cycle
Syntax:
This cycle is used for stock removal in parallel tool
G90 X_ Z_ F_ path.
X= Diameter to which movement is 1. Rapid to x position
2. Feed to Z position
being made
3. Feed to start X position
Z= Co-ordinate in Z-axis
4. Rapid to start Z position
F= Feed rate
ϕ 25 Tool
Example:
G21 G98 X21 ϕ 15
X (+)

ϕ 20
G28 U0 W0 X20
M06 T0101 G90 X19 Z -17 F60
M03 S2500 X18 Z (+)
G00 X26 Z2 X17
G94 X0 Z -0.5 F60 X16
Z-1 X15
Z-1.5 G28 U0 W0 2 mm
Z-2 M05 15 15 facing
G00 X25 Z0 M30
G90 X24 Z -32 F60
X23
X22

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 Mechanical Engineering
Department; Thapar
University G71 – Multiple Turning Cycle
Syntax: This cycle is used when major direction of cut along
G71 U_ R_ the “Z” axis

G71 P_ Q_ U_ W_ F_

U= depth of each cut (First one)

R= Tool retract G70 – Finishing cycle

P= Start block of the profile
Syntax:
Q= Finishing block of the profile
G70 P_ Q_ F_
U= Finishing allowance in X axis (Second one)

W= Finishing allowance in Z axis P= Start block of the profile

F= Feed rate Q= Finishing block of the profile

F= Feed rate

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Mechanical Engineering
Department; Thapar
University
Example

O0001
G21 G98
G28 U0 W0
M06 T0101
M03 S1500 /Spindle clockwise with 1500 RPM
G00 X32 Z5 /Tool Moving to Tool Entry Point of X32 Z5 at
Rapid Traverse
G71 U0.5 R1 /Calling G71 Cycle and defining Cycle Parameters
X G71 P1 Q2 U0.1 W0.1 F100 /Defining Cycle Parameters
Z N1 G01 X18 F100
G01 Z0
G01 X20 Z-4
G01 Z-16
G03 X24 Z-20 R4
G01 Z-30
N2 G01 X32 Z-38
G70 P1 Q2 F80 /Finishing cycle
G28 U0 W0
M05
M30

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 Mechanical Engineering
Department; Thapar
University G74 – Multiple Drilling Cycle

G74 R_  This cycle is designed for deep hole drilling

G74 X_ Z_ Q_ F
R - Return Amount, mm 1. The drill enters the w/p into a
X - Always Zero, mm predetermined a amount
Z - Drilling Depth, mm 2. Then backing off another set amount
Q - Depth of Cut in Z axis (in Micron)
to remove the chips
F - Feed Rate, mm

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 Mechanical Engineering
Department; Thapar
University G74 – Multiple Drilling Cycle
ϕ25
X (+)
G74 R_
G74 X_ Z_ Q_ F
Z (+)

Example:
Drill
G21 G98
G28 U0 W0
M06 T0202 / Call tool no. 2
12
M03 S1000 / Rotate tool at a speed of 2500 rpm 50

G00 X0 Z5 / Tool Moving to Tool Entry Point of X0 Z5 at Rapid Traverse

G74 R1 / Calling G74 Cycle and defining parameters
G74 X0 Z-12 Q500 F100 / make drill upto 12 mm with 500 mm doc
G28 U0 W0
M05
M30

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 Mechanical Engineering
Department; Thapar
University G76 – Multiple Threading Cycle

G76 P(m) (r) (a) Q_ R_ D= Major Diameter

P= Thread Height
G76 X_ Z_ P_ Q_ F_
Thread Height, P = 0.613 x Pitch of
the Thread
m= no of passes for finishing operation Core dia= D – 2 (P)
r= tool relief angle
a= thread angle, degree Pitch
Q= minimum cutting depth (mm in software)
(mm in machine) Thread
Height
R= finishing allowance (in mm)
X= core diameter (in mm) Thread
angle
Z=Thread length, mm
Q= depth of cut for first pass (mm in software/ mm in m/c)
P=thread height (mm in software/ mm in machine)
F= Pitch
 Mechanical Engineering
Department; Thapar
University Example
M32×1.5 mm

Thread Height, P = 0.613 x Pitch of the Thread

= 0.613 x 1.5
P = 0.919 mm =919 mm

Core diameter = Major dia – 2 (P)

= 32 – 2 (0.919)
= 32 – 1.818
= 30.162 mm

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Mechanical Engineering
Department; Thapar
University

G21 G98 ------ Initial Settings

G28 U0 W0 ------ Going to home position
M06 T0101 ------ Tool Change Position No. 01
M03 S1500 ------ Spindle clockwise with 1500 RPM
G00 X32.5 Z5
G76 P040060 Q50 R0.04 ------ Calling G76 cycle
G76 X30.162 Z-14 P919 Q100 F1.5
G28 U0 W0
M05
M30

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 Mechanical Engineering
Department; Thapar
University
Different Measurement System
Absolute System Incremental System
 Absolute dimension system always refers  Every measurement is considered from
to a fixed reference point in the drawing. previously dimensioned position.
 This point has the function of a coordinate  Incremental dimensions are distance
zero point. between adjacent points.
 Define by X and Z  Defined by U and W

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 Mechanical Engineering
Department; Thapar
University Practice
ϕ 32
R6
ϕ 20

ϕ 12 M 12×1.5

X
Z
21 3 3 15

O0001 G70 P1 Q2 F100 /Finishing cycle

G21 G98 G28 U0 W0
G28 U0 W0 M06 T0303 /Calling threading tool
M06 T0101 M03 S500 / Spindle clockwise rotation
M03 S1500 /Spindle clockwise with 1500 RPM G00 X13 Z0
G00 X32 Z2 /Tool Moving to Tool Entry Point of X32 Z5 at G76 P040060 Q50 R0.4 / Call & execute threading cycle
Rapid Traverse G76 X10.162 Z-15 Q100 P919 F1.5
G71 U0.5 R1 /Calling G71 Cycle and defining Cycle Parameters G28 U0 W0 / Tool home position
M05
G71 P1 Q2 U0.1 W0.1 F100 /Defining Cycle Parameters
M30
N1 G01 X12 F100
G01 Z0
G01 X12 Z-18
G01 X20 Z-21
G01 X20 Z-42
N2 G01 X 32 Z-42

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Mechanical Engineering
Department; Thapar
University
Degree of Freedom in Milling

End milling tool

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 Mechanical Engineering
Department; Thapar
University
Various Operations That Can Be Performed in Milling

End Milling Chamfer Milling Face Milling

 A end mill axials  A chamfer end  A face mill machines
axial cuts across mill makes a cut a flat surface of the
the workpiece along an edge of workpiece in order to
 Machine a feature, the workpiece provide a smooth
such as a profile,  Create an angled finish.
slot, pocket, or surface, known
even a complex as a chamfer.
surface contour

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 Mechanical Engineering
Department; Thapar
University
Various Operations That Can Be Performed in Milling

Drilling

Boring Reaming

Tapping

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 Mechanical Engineering
Department; Thapar
University
Workpiece zero points or Program zero point

Z (+) Tool

X (+)
Thickness

Z (+)
Zero point

Length
Workpiece Y(+)
X (+)

Y (+)

X (+)
(0,0)
Width

48
 Mechanical Engineering
Department; Thapar
University
CNC Milling – G Code

 G90 – Absolute method

 G91 – Incremental method
 G94 – Feed, mm/min
 G95 – Feed, mm/rev
 G54 to G59 – Work coordinate system
 G43 – Height offset in downward direction
 H1 to H6 – Height offset for tool
 X – Absolute mode in X- axis
 Y – Absolute mode in Y- axis
 Z - Absolute mode in Z- axis

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Mechanical Engineering
Department; Thapar
University

G01
G00

G01 X_ Y_ Z_ F_
G00 X_ Y_ Z_

G03 X_ Y_ Z_ F_
G02 X_ Y_ Z_ F_

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 Mechanical Engineering
Department; Thapar
University

O0002
G21 G94
G91 G28 X0 Y0 Z0 /tool go to home position
M06 T0101 / Call tool no. 1
M03 S2500 / tool rotates at a speed of 2500 rpm
G00 G90 G54 X0 Y0 /
G00 G43 H1 Z10
G00 X20 Y10
G01 Z-2 F100
G01 X10 Y20
G01 Y80
G02 X20 Y90 R10
G01 X80
G03 X90 Y80 R10
G01 Y20
Thickness of workpiece: 12 mm, Depth of cut: 1 mm, G01 X80 Y10
Feed rate: 100 mm/min, Speed: 2500, Dia of end mill: 5 mm G01 X20
G00 Z5
G91 G28 X0 Y0 Z0
M05
M30

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