CAD and CAM Mechanical Shop Report

8/4/2019 CAD and CAM Mechanical Shop Report

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CAD\CAM LAB REPORT

MILLING AND TURNING (workshop)

TP015352

UC2F0812ME

(Done under supervision of Mr. Jupry)



ContentsIntroduction: .....................................................................................................................................3

Milling: ...................................................................................................................................................... 3

Classification of milling: ............................................................................................................................ 3

Peripheral milling .................................................................................................................................. 3

Face Milling ........................................................................................................................................... 3

End Milling ............................................................................................................................................ 4

Methods of milling: ................................................................................................................................... 4

Up Milling .............................................................................................................................................. 4

Down Milling ......................................................................................................................................... 4

CNC Milling: ............................................................................................................................................... 5

Milling Machine: ....................................................................................................................................... 7

Types of Milling Cutters: ........................................................................................................................... 8

Types of Milling Machines: ....................................................................................................................... 9

Turning: ................................................................................................................................................... 11

Lathe (Turning Machine): ........................................................................................................................ 13

Chucks: .................................................................................................................................................... 15

Three-Jaw Chuck ................................................................................................................................. 15

Four-Jaw Chuck ................................................................................................................................... 16

Turning Categories: ................................................................................................................................. 16

Objective: ........................................................................................................................................ 17

Process: ........................................................................................................................................... 17

Product Designs (CAD): .................................................................................................................... 18

Milling: .................................................................................................................................................... 18

Turning: ................................................................................................................................................... 23

Final Parts: ............................................................................................................................................... 25

Inspection Table: ............................................................................................................................. 27

Milling Part: ............................................................................................................................................. 27

Turning Part: ........................................................................................................................................... 27

Conclusion: ...................................................................................................................................... 28

References: ...................................................................................................................................... 28



Introduction:

Milling: It is the process of cutting away material by feeding a work piece past a rotating multiple tooth

cutter. The cutting action of the many teeth around the milling cutter provides a fast method of machining. The machined surface may be flat, angular, or curved. The surface may also be milled to any

combination of shapes. The machine for holding the work piece, rotating the cutter, and feeding it is

known as the

Classification of milling:

Peripheral milling

In peripheral (or slab) milling, the milled surface is generated by teeth located on the periphery of the

cutter body. The axis of cutter rotation is generally in a plane parallel to the work piece surface to be

machined.

Face Milling

In face milling, the cutter is mounted on a spindle having an axis of rotation perpendicular to the work piece surface. The milled surface results from the action of cutting edges located on the periphery and

face of the cutter.



End Milling

The cutter in end milling generally rotates on an axis vertical to the work piece. It can be tilted to machine

tapered surfaces. Cutting teeth are located on both the end face of the cutter and the periphery of the cutter

body.

Methods of milling:

Up Milling

Up milling is also referred to as conventional milling. The direction of the cutter rotation opposes the feed

motion. For example, if the cutter rotates clock wise , the work piece is fed to the right in up milling.

Down Milling

Down milling is also referred to as climb milling. The direction of cutter rotation is same as the feed

motion. For example, if the cutter rotates counter clock wise, the work piece is fed to the right in down

milling.



The chip formation in down milling is opposite to the chip formation in up milling. The figure for down

milling shows that the cutter tooth is almost parallel to the top surface of the work piece. The cutter tooth

begins to mill the full chip thickness. Then the chip thickness gradually decreases.

(http://www.mfg.mtu.edu/marc/primers/milling/index.html accessed on 19th NOV, 2009)

CNC Milling:

Computer Numerical Control (CNC) Milling is the most common form of CNC. CNC mills can perform

the functions of drilling and often turning. CNC Mills are classified according to the number of axes that

they possess. Axes are labeled as x and y for horizontal movement, and z for vertical movement, as

shown in this view of a manual mill table A standard manual light-duty mill is typically assumed to have

four axes:

1. Table x.

http://www.mfg.mtu.edu/marc/primers/milling/index.html






2. Table y.

3. Table z.

4. Milling Head z.

The number of axes of a milling machine is a common subject shop talk and is often interpreted invarying ways. We present here what we have seen typically presented by manufacturers. A five-axis CNC

milling machine has an extra axis in the form of a horizontal pivot for the milling head, as shown below.

This allows extra flexibility for machining with the end mill at an angle with respect to the table. A six-

axis CNC milling machine would have another horizontal pivot for the milling head, this time

perpendicular to the fifth axis.

CNC milling machines are traditionally programmed using a set of commands known as G-codes. G-

codes represent specific CNC functions in alphanumeric format.

(http://www.efunda.com/processes/machining/mill_cnc.cfm accessed on 19th NOV, 2009)

http://www.efunda.com/processes/machining/mill_cnc.cfm






Milling Machine:

It is a machine tool used for the shaping of metal and other solid materials. Milling machines exist in two

basic forms: horizontal and vertical, which terms refer to the orientation of the cutting tool spindle. Unlike

a drill press, in which the work piece is held stationary and the drill is moved vertically to penetrate thematerial, milling also involves movement of the work piece against the rotating cutter, the latter of which

is able to cut on its flanks as well as its tip. Work piece and cutter movement are precisely controlled

usually by means of precision ground slides and lead screws or analogous technology. Milling machines

may be manually operated, mechanically automated, or digitally automated via computer numerical

control (CNC).

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

cutting, planing, drilling, die sinking, rebating, routing, etc. Cutting fluid is often pumped to the cutting

site to cool and lubricate the cut, and to sluice away the resulting swarf.

(http://en.wikipedia.org/wiki/Milling_machine accessed on 19th NOV, 2009)

http://en.wikipedia.org/wiki/Machine_tool

http://en.wikipedia.org/wiki/Metal

http://en.wikipedia.org/wiki/Solid

http://en.wikipedia.org/wiki/Materials

http://en.wikipedia.org/wiki/Drill#Drill_press

http://en.wikipedia.org/wiki/Leadscrew

http://en.wikipedia.org/wiki/Computer_numerical_control


http://en.wikipedia.org/wiki/Cutting_fluid

http://en.wikipedia.org/wiki/Swarf

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





http://en.wikipedia.org/wiki/Cutting_fluid



http://en.wikipedia.org/wiki/Leadscrew

http://en.wikipedia.org/wiki/Drill#Drill_press

http://en.wikipedia.org/wiki/Materials

http://en.wikipedia.org/wiki/Solid





Types of Milling Cutters:



Types of Milling Machines: Milling machines are among the most versatile and useful machine tools due to their capabilities to

perform a variety of operations. They can be broadly classified into the following types:

1. Column and knee type of milling machines

2. Bed type

3. Rotary table

4. Tracer controlled

Horizontal Milling Machine Vertical Milling Machine

Column & Knee type Milling Machines:

Used for general purpose milling operations, column and knee type milling machines are the most

common milling machines. The spindle to which the milling cutter is may be horizontal (slab milling) or

vertical (face and end milling). The basic components are:

a. Work table, on which the work piece is clamped using the T-slots. The table moves longitudinally

with respect to the saddle.



b. Saddle, which supports the table and can move transversely.

c. Knee, which supports the saddle and gives the table vertical movements for adjusting the depth of

cut.

d. Over arm in horizontal machines, this is adjustable to accomadate different arbor lengths.

e. Head, which contains the spindle and cutter holders. In vertical machines the head may be fixed

or vertically adjustable.

1. Bed type Machines:

In bed type machines, the work table is mounted directly on the bed, which replaces the knee, and

can move only longitudinally. These machines have high stiffness and are used for high

production work.

2. Planer Machines

Planer machines are similar to bed type machines but are equipped with several cutters and headsto mill various surfaces.

3. Rotary Table Machines

Rotary table machines are similar to vertical milling machines and are equipped with one or more

heads to do face milling operations.

4. Tracer Controlled Machines

Tracer controlled machines reproduce parts from a master model. They are used in the

automotive and aerospace industries from machining complex parts and dies.



5. Computer Numerical Control (CNC) Machines

Various milling machine components are being replaced rapidly with computer numerical control(CNC) machines. These machine tools are versatile and are capable of milling, drilling, boring

and tapping with repetitive accuracy.

Turning:

It is another of the basic machining processes. Turning produces solids of revolution which can be tightly

tolerance because of the specialized nature of the operation. Turning is performed on a machine called a

lathe in which the tool is stationary and the part is rotated. The figure below illustrates an engine lathe.

Lathes are designed solely for turning operations, so that precise control of the cutting results in tight

tolerances. The work piece is mounted on the chuck, which rotates relative to the stationary tool.

It is the process whereby a single point cutting tool is parallel to the surface. It can be done manually, in a

traditional form of lathe, which frequently requires continuous supervision by the operator, or by using a

computer controlled and automated lathe which does not. This type of machine tool is referred to as

having computer numerical control, better known as CNC and is commonly used with many other types

of machine tool besides the lathe.

When turning, a piece of material (wood, metal, plastic even stone) is rotated and a cutting tool is

traversed along 2 axes of motion to produce precise diameters and depths. Turning can be either on the

outside of the cylinder or on the inside (also known as boring) to produce tubular components to various

geometries. Although now quite rare, early lathes could even be used to produce complex geometric

figures, even the platonic solids.

The turning processes are typically carried out on a lathe, considered to be the oldest machine tools, and

can be of four different types such as straight turning, taper turning, profiling or external grooving. Those

types of turning processes can produce various shapes of materials such as straight, conical, curved, or

grooved work piece. In general, turning uses simple single-point cutting tools. Each group of work piece

materials has an optimum set of tools angles which have been developed through the years.



http://en.wikipedia.org/wiki/Material

http://en.wikipedia.org/wiki/Wood


http://en.wikipedia.org/wiki/Tool_bit

http://en.wikipedia.org/wiki/Boring

http://en.wikipedia.org/wiki/Platonic_solids

http://en.wikipedia.org/wiki/Platonic_solids

http://en.wikipedia.org/wiki/Boring

http://en.wikipedia.org/wiki/Tool_bit


http://en.wikipedia.org/wiki/Wood

http://en.wikipedia.org/wiki/Material





The bits of waste metal from turning operations are known as chips, or swarf. In some areas they may be

known as turnings.

The term facing is used to describe removal of material from the flat end of a cylindrical part, as shown

below. Facing is often used to improve the finish of surfaces that have been parted.





(http://www.efunda.com/processes/machining/turn_engine_lathe.cfm accessed on 19th NOV, 2009)

Lathe (Turning Machine):

A lathe is a machine tool used principally for shaping pieces of metal, wood, or other materials by causing

the work piece to be held and rotated by the lathe while a tool bit is advanced into the work causing the

cutting action. Lathes can be divided into three types for easy identification: engine lathe, turret lathe, and

special purpose lathes. Some smaller ones are bench mounted and semi-portable. The larger lathes are floor

mounted and may require special transportation if they must be moved. Field and maintenance shops

generally use a lathe that can be adapted to many operations and that is not too large to be moved from one

work site to another. The engine lathe is ideally suited for this purpose. A trained operator can accomplish

more machining jobs with the engine lathe than with any other machine tool. Turret lathes and special

purpose lathes are usually used in production or job shops for mass production or specialized parts, while

basic engine lathes are usually used for any type of lathe work. Below is the diagram of the engine lathe:

http://www.efunda.com/processes/machining/turn_engine_lathe.cfm



http://en.wikipedia.org/wiki/Engine_lathe

http://en.wikipedia.org/wiki/Turret_lathe

http://en.wikipedia.org/wiki/Mass_production

http://en.wikipedia.org/wiki/Mass_production

http://en.wikipedia.org/wiki/Turret_lathe

http://en.wikipedia.org/wiki/Engine_lathe






Chucks:

The chuck is integral to a lathe's functioning because it fixtures the part to the spindle axis of the machine.

Below is shown a three-jaw chuck with jaws that are all driven by the same chuck key. This arrangement

provides convenience in that parts can be mounted and dismounted quickly.

Three-Jaw Chuck

The inner construction of the three-jaw chuck is shown below. A spiral gear meshes with cog teeth on the

aws to move all three jaws in or out simultaneously. Parts can be fixed on outer or inner surfaces since

there are gripping surfaces on the inner and outer surfaces of the chuck jaws.



Four-Jaw Chuck

If the part needs to be off center or is not a solid of revolution (axially symmetric), a four-jaw chuck with

independently-actuated jaws needs to be used. Such a chuck is depicted below.

Turning Categories:



Objective:

Our objective is to develop 2 products one by milling using the milling machine and other one by using

lathe. These products have to be same as the products designed by us using Autodesk inventor. Then we

need to inspect these products results.

Process:

For milling our product we placed our rectangular flat piece on the table in milling machine. Then using

the drill, x, y and z handles we moved our piece sideways or forward and backward and engraved or cut

out the design needed by us on the rectangular steel piece provided to us. Then we used the drill machine

to create holes in our product. At end we used filer to give the finishing touches to our product and used

8.5mm thread tool (drill to) make threading inside the holes.



For turning our product we placed our cylindrical piece in chucks of the lathe machine. Then using the

carbon-steel sharp tool we turned our piece to get the design we needed.

Product Designs (CAD):

Milling:





(Various views of our products 3D model)





(Various sketches of our product along with dimensions)



Turning:

(Various views of our products 3D model)





(Various sketches of our product along with the dimensions)

Final Parts:





Inspection Table:

Milling Part:

P.S: All dimensions are in mm

Autodesk Inventor Mechanical Lab

Length of part 75 74.9

Breadth of part 75 75

Height of part 25 24

Length of pocket 75 74.9

Breadth of pocket 45 46

Height of pocket inside 5 6

Height top surface till

pocket

20 18

Height of edges left and right of the piece

15,15 14,15

Height of top surfacetill left and right edges

10 11,10

Breadth of right andleft edges

15,15 16,14

Turning Part:

P.S: All dimensions are in mm and reference from pt. tip going to the end

Autodesk Inventor Mechanical Lab

Length 1 10 10

Length 2 30 30

Length 3 25 25

Length 4 35 35

Length 5 20 20

Length of piece 100 100

Diameter 1 10 10.2

Diameter 2 13 13.1Diameter 3 22 21.9

Diameter 4 30 29.8

Diameter 5 20 20.2

Angle of pointed tip 30 degrees 35 degrees



Conclusion:

After doing this assignment I can design products using Autodesk Inventor and then using the lathe

(turning) machine and milling machine I can design or develop the products in the real life. This

assignment is going to help me a lot in future if I go into manufacturing or design industry.

References:

(http://www.efunda.com/processes/machining/mill_cnc.cfm accessed on 19th

NOV, 2009)

(http://www.mfg.mtu.edu/marc/primers/milling/index.html accessed on 19th

NOV, 2009)

(http://en.wikipedia.org/wiki/Milling_machine accessed on 19th NOV, 2009)

(http://www.efunda.com/processes/machining/turn_engine_lathe.cfm on 19th

NOV, 2009)

(http://en.wikipedia.org/wiki/Turning on 19th NOV, 2009)

(http://web.mit.edu/2.670/www/Tutorials/Machining/lathe/Description.html on

19th NOV, 2009)













http://en.wikipedia.org/wiki/Turning



http://web.mit.edu/2.670/www/Tutorials/Machining/lathe/Description.html









Documents

CAD and CAM Mechanical Shop Report