This was a Live project done at Ordnance Factory Medak (OFMK). It is a report on Design, Manufacture & New Process chart of a Fixture Required for the Job Operations on a "Lower Race Ring sl.no-675-58-133" (work piece) in BMP-2 ICV.

1. A Mini-project report on
Fixture Design of Lower Race Ring on BMP-2
(For New CNC VTL from HMT)
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by
MOHAMMED SHAROOQ JAFFER SIDDIQUE
(14401A0392)
Under the Guidance of
Mr. CH. SANDEEP
(Associate Professor)
DEPARTMENT OF MECHANICAL ENGINEERING
DVR COLLEGE OF ENGINEERING & TECHNOLOGY
(Affiliated to JNTUH, Approved by AICTE, New Delhi)KASHIPUR
SANGAREDDY, Pin -502285.
2017-2018
1

2. DEPARTMENT OF MECHANICAL ENGINEERING
DVR COLLEGE OF ENGINEERING & TECHNOLOGY
(Affiliated to JNTUH, Approved by AICTE, New Delhi)
KASHIPUR, KANDI, SANGAREDDY.
CERTIFICATE
This is to certify that the project report entitled “Fixture Design of Lower Race
Ring on BMP-2 (For New CNC VTL from HMT)” is being submitted by
MOHAMMED SHAROOQ JAFFER SIDDIQUE (14401A0392) in fulfilment of the
award of degree of Bachelor of Technology in Mechanical Engineering. The result
embodied in this report has not been submitted to any other university or institute for the
award of any degree.
Internal Guide Head of the
department
(Mr. CH. SANDEEP) (Mr. A. RADHA
KRISHNA)
2

3. External Examiner
3

4. ACKNOWLEDGEMENT
The satisfaction and euphoria that accompany the successful completion of any task
would be incomplete without the mentioning of the people whose constant guidance and
encouragement made it possible. We take pleasure in presenting before you, our project,
which is a result of studies of both research and knowledge.
We express our earnest gratitude to our internal guide, Mr. CH. SANDEEP,
(Associate professor, Department of Mechanical Engineering), our project guide for his
constant support, encouragement and guidance. We are grateful for his cooperation and
his valuable suggestions.
We express our sincere thanks and regards to Dr. M.J. PRAKASH (Principal),
Mr. A. RADHA KRISHNA,(Professor and Head of Department) and college
management for all their support and encouragement.
Finally, I express my gratitude to all other members who are involved either
directly or indirectly for the completion of this project.
4

5. ABSTRACT
The lower race ring is a component which is assembled on the turret at the commander’s
compartment in BMP-2 (Boyevaya Mashina pekhoty) ICV (Infantry Combat Vehicle).
Currently the lower race ring is being produced by a set of operations performed in two
Kirloskar Vertical Machining Centers sl.no 1951 & 1952.These machines do not have
Automatic Tool Change (ATC) and lack live tool facility due to which drilling and
milling operations are performed on another Numerical Control (NC) Vertical Milling
Centre (VMC). This procedure consumes a significant amount of cost and man-hours. A
new robust CNC Vertical Turning Lathe machine (VTL) has been provided to the
operators from Hindustan Machine Tools (HMT) which has live tool facility, Automatic
Tool Change and can perform drilling, milling, tapping operations very effectively. This
project is based on a fixture design and process chart which can satisfy the operations
required to be performed on the work job to produce an “excellent finish lower race ring”
and significant reduction of cost and man-hours required compared to previous
procedure.
5

6. 6

7. INDEX
CONTENTS
CHAPTER-1 Page No.
Introduction
1.0 Ordanance factory medak (OFMK) 1
1.1 History 1
1.2 Products 1
1.3 Sections in ordnance factory 5
1.4 Mission 5
1.5 Vision 5
1.6 Sarath BMP (Boyevya Mashina Pekhoty)-2 6
CHAPTER-2
Lower Race Ring
2.0 Statement of problem being solved 8
2.1 Sarath BMP-2 Armored Dozer 9
2.2 CNC VMC 10
2.3 Current Maintenance Situation of CNC VMC’s 11
CHAPTER-3
Problem Solution
3.0 CNC VTL (Vertical Turning Lathe) 12
3.1 CNC VTL Specifications 12
3.2 Advantages 13
CHAPTER-4
Process chart of Lower Race Ring
4.0 Process chart table & Drawing 15
4.1 Demonstrating Fixture Design in CAD 20
4.2 CNC Programming Guide Codes 24
7

8. 4.3 Sample CNC VTL Programming 32
CHAPTER-5
Conclusion 36
8

9. List of figures Page No.
1.1 BMP-2 in Hull & Turret section 1
1.2
• Sarath BMP-2 & BMP- 2K 2
• Armored Ambulance 2
• AAD 3
• ARV 3
• NBCRV 4
• CMT 4
• CRN91 Naval Gun 5
2.0 Lower Race Ring 8
2.1 Lower Race Ring Sleeve 9
2.2 CNC VMC Sl.no- 1951 & 1952 10
3.0 CNC VTL 12
4.0
• Blank Job 15
• Finished Job 15
• Operation- 1 (675-58-133) 18
• Operation- 3 18
• Operation- 4 19
• Operation- 5 20
4.1
• CAD Demonstration of Fixture 20
• Job Operation- 1 21
• Job Operation- 2 21
• Fixture Thickness & Dimensions 22
• Clamps Demonstration 23
List of tables Page No.
9

10. 4.0 Process chart Table 16
10

11. Chapter- 1
INTRODUCTION
1.0 Ordnance factory medak(OFMK)
previously called ordnance factory project Medak (OFMP), while in its development
stage is a company that manufactures armored vehicles and is one of the 41 Indian
ordnance factory under ordnance factories board of the ministry of defense controlled
by government of India.
It is spread over an area of three 3023 acres and has employee strength of about 4000
persons. The company is headed only by an IOFS officer called the chief executive
officer responsible for the overall management of the company and is the main
judicial authority.
OFMK is the only manufacturer of infantry combat vehicles (ICVs) in India.
1.1 HISTORY:
It was established on 19 July 1984 by the Prime Minister of India, Indira Gandhi for
the indigenous production of infantry combat vehicles.
BMP-2 in Hull & Turret section
1.2 PRODUCTS:
Over the decades, the company has diversified its products range, manufacturing
surface-to-air missile(SAM) launchers, armored ambulances-propelled howitzers,
armored cars, unmanned ground vehicles(UGVs), armored light recovery vehicles,
NBC recce vehicles, mine protected vehicles, armored amphibious dozers, armored
radars, naval armaments etc.
11

12. • BMP-2 Sarath (chariot of victory) - Indian license-produced variant of the BMP-2,
built by ordnance factory medak. The first vehicle, assembled from components
supplied by KBP, was ready in 1987. By 1999. About 90% of the complete vehicle
and its associated systems were being produced in India. It is estimated that by 2007.
1.250 vehicles had been built. India has also developed the following version of the
sarath.
• BMP-2K sarath – Command vehicle, similar to the soviet/Russian version.
12

13. • Armoured Ambulance – This version retains the turret but without the gun or
smoke grenade launchers. The troop compartment has been modified to carry four
stretchers.
• Armouored Amphibious Dozer (AAD) – Turretless combat engineer vehicle, fitted
with a folding dozer blade at the rear, mine plugs, a main winch with of 8000kg and
a rocket propelled earth anchor for self-recovery.
• Armoured Engineer Reconnaissance Vehicle (AERV) – This version has no gun
and is fitted with specialized equipment. Including an echo sounder, a water current
meter,a laser range finder and GPS. On the left rear of the hull a marking with forty
rods is fitted.
13

14. • NBC Reconnaissance Vehicle (NBCRV) – For detection of nuclear, biological and
chemical contamination. The NBCRV was developed by DRDO and VRDE, it has
been ordered by the Indian army.
• Carrier Mortar Tracked Vehicle (CMT) – This turretless version has a mortar
mounted in the modified troop compartment the mortar is fired through an opening
in the hull roof that two hinged doors, it has a max range of 5000m and normal rate
of fire of 6-8 RDS/min. This is also a long range version of the mortar, the vehicle
carries 108 mortar rounds and is also fitted with a 7.62mm machine gun with 2.350
rounds. Crew : 2+4. The first prototype was completed in 1997.
14

15. • CRN 91 Naval Gun – The close range naval 91 is a naval version of the medak
30mm automatic gun installed on the sarath infantry fighting vehicle, a variant of the
Russian (orginally soviet) BMP-2 manufactured in India under license by the
Ordanance Factory Medak. The medak gun itself is based on the Russianship UNOV
2A42 30mm automatic cannon.
1.3 Sections in ordnance factory:
1. Foundry
2. Heavy machine shop
3. Light machine shop
4. Sheet metal shop
5. Tool room
6. Vehicle assembly
7. Final acceptance
15

16. 1.4 MISSION:
“Production of State of the Art Battle-field Equipment.”
1.5 Vision:
• To equip or armed forces with modern defense and battlefield equipment.
• To continuously modernize our production facilities.
• To equip ourselves with technologies through acquisition, synergy and in-house
R&D.
1.6 SARATH BMP (BOYEVAYA MASHINA PEKHOTY)-2:
Sarath bmp-2 is the best infantry combact vehicles in the world with modern weapon
systems .It is ideal for fighting night battels with speed, surprise and deadly precision.
Main components of BMPT-2
• Power unit
• Powertrasmission
• Track and suspension system
• Water bilge pumps and drinage devices
• Electrical equipment
• Communication facilities
• Fire fighthing equipments
• Screening equipments systems
• MBC protection and crew llife support system
16

17. TECHNICAL SPECIFICATION OF BMP-2
• Crew capacity: driver,gunner,commander,7 crews
• Combact loaded mass,14 tonns+2%
• Overall length 6735mm
• Overall width 3150mm
• Overall height 2600mm
• Engine power 300HP
• Maximum speed on road 65kmph
• Cross country speed 45kmph
• Maximum speed into water 7kmph
• Ground clearance 420mm
• Vertical obsticles 0.7m(max)
• Trench crossing 2.5m
• Gradient 35 degrees
• Average fuel consumption for 100km is 92liters
• Automatic gun 2A42:30mm caliber
• Rate of firing in slow mode: 200-300 rounds per minute
• Rate of firing in rapid mode:5550 roundsmin
• Firing rage 4km
17

18. • Coaxial machine gun PKT-7.62 caliber
• Rate of fire 700-800 roundsmin
• ATGM launches firing range- 4kms
• Communication system:radio set tadran for external communications and R174
for internal communications
18

19. Chapter- 2
LOWER RACE RING (675-58-133)
2.0 statement of problem being solved
Lower race ring is a vehicle assembly component which is being
manufactured in the hull and turret section (HTM). It is assembled on the
turret at the commander’s compartment of infantry combat vehicle
(BMP-2) dozer. The lower race ring acts like a base and allows the
commander to rotate the upper dressing of the lower race ring on a total
of 360 degrees.
Lower race ring
19

20. 2.1 Sarath (BMP-2) armoured dozer
• The lower race ring has a radial boring diameter of 13mm and holds
90 molybdenum disulphate balls for rotation purpose between the
ring and the dressing.
• The dressing sleeve which assembles on the lower race ring is made
up of aluminium and special steel alloy where as the upper covering
door which gives access to the commander’s compartment is made
up of hardened armored steel for bullet protection.
Lower race ring dressing (sleeve)
• Currently the lower race ring is being manufactured by a set of
operations in two vertical machining centres sl.no 1951 & 1952. The
two machines are of same make and type. Below are the
specifications of these machines
20

21. 2.2 Computer Numerical Controlled (CNC) Vertical Machining Centre
(VMC):
• Manufacturer - kirloskar
• Main driving power - 105kw
• Diameter of the chuck - 900mm
• Load capacity – 7500 Kg
• CNC system - sinumerik
• Axes – x axis
Z axis
B axis
• Spindle speed – 5-2500rpm
• No. of tools in magazine – 12
• Tool measuring system – No
• Automatic Tool Changer (ATC)0 – No
• Live tool attachment head – No
• Manual Tool Changer (MTC) - Yes
21

22. (CNC VMC sl.no- 1951 & 1952)
22

23. 2.3 Current maintenance situation of CNC VMC’s:
• These machines are in service from the start of OFMK, I.e., 33 years,
where as the limited period of service provided to the machine is 25
years as per the manufacturer’s details.
• From the above line it can be clearly noted that further usage of the
machines can effect the finish and accuracy in the dimensions of the
work job.
• The machines does not have an automatic tool change facility, due to
this inability the operators have to change the tools manually
according to the operations or arrange the similar tool operations in a
set.
• The machines lack live tool head due to which the drilling and milling
operations have to be performed on another vertical milling centre.
This inability of the CNC machine consumes significant amount of
cost and man-hours.
• As the work job undergoes multiple changes in the fixtures and
machining centres it consumes increased amount of time as the
expected time for a job to be completed is 30-40 minutes.
23

24. Chapter-3
Problem solution
3.0 CNC VTL (Vertical Turning Lathe)
• A new robust Computer Numerical Controlled(CNC) Vertical Turning Lathe
Machine (VTL) has been provided to the operators from Hindustan Machine Tools
(HMT). This machine is capable of performing all the extra operations which the
previous machines lack. The machine specifications are listed below.
24

25. CNC Vertical Turning Lathe (VTL)
3.1 CNC Vertical Turning Lathe Machine Specifications :
• Make – Hindustan Machine Tools (HMT)
• Main driving power – 180 Kw
• Length of bed – 2000 mm
• Table width- 3000 mm
• Load capacity- 900 Kg
• CNC system- Sinumerik 840D
25

26. • Accuracy position-
X-axis
Z-axis
B-axis
C-axis
• Spindle turning speed range- 2500 – 3000 rpm
• No. of tools in magazine- 81
• No. of spindle attachable- 2
• Llive tool facility- yes
3.2 Advantages:
• This machine has Automatic tool change (ATC) facility which is very helpful
equipment for the operator to reduce the time required by the job to be done.
• It has live tool head facility which can perform drilling, milling, tapping, turning
and taper operations which is a major plus point and reduces the need to get the
job done on a separate milling centre. This greatly reduces man-hours and cost
required for production of the job.
• The fixture design shown in this report is capable of effectively performing the
turning, drilling, milling, tapping and taper operations on a single fixture which
also reduces the man-hours and cost.
• Performing all the operations on a single machine saves lots of room space and
electricity.
26

27. • The maintainence cost for a single machine is less compared to three machines.
• The new VTL is updated with sinumeric 840D which is very user friendly, fast and
can measure the tool length effectively.
• The blank job of the lower race ring is an alluminium alloy casting. It is produced
in foundry section. It has dimensions upto dia 690 & dia 619 and has a thickness of
40. All measurements are taken in mm.
27

28. Chapter- 4
PROCESS CHART FOR LOWER RACE RING:
4.0 Process Chart Table with Drawing
Blank job
28

29. Finished job (675-58-133)
29

30. 30
Sl.no Description of operation Work
centre
Description of
tool
Inspection
1 Face observing thickness 40mm, bore
the inner diameter according to the
fixture diameter.
CNC VTL
chuck jaws
Face mill, boring
tool
Vernier callipers
2 Turn observing outer dia 684 CNC VTL
(fixture 1)
Turning tool verniers
3 Mill 4 slots to 10mm depth observing
678+_0.5X230+_0.5mm, form a 15
degree chamfer along dia684
CNC VTL(
fixture 1)
End mill cutter,
15deg chamfer tool
Vernier calliper
4 Tap drill 17 holes at 675dia observing
665p.c.d to 20mm depth and c.s.k to
1.6X45degrees (tap 17 holes 6.75dia to
M8 X 1.25.7H to 14mm), enlarge dia
620 upto dia625 and form a chamfer.
CNC VTL
(fiture 1).
Drill 6.7001A
Csk tool
1300X90degrees
Tap (M8 X 1.25-7H)
15deg Chamfer tool
Thread plug guage
M8 X 1.25-7H.
5 Invert the job ans Turn upto
dia(-1) upto depth of 2mm
and turn further as a
partition turning of dia667(-
1) upto 10mm depth. Form
a taper of 45degrees from
dia 675 to dia684, form
chamfer of 15deg at dia670
CNC VTL
(fixture 1)
Turning tool Vernier callipers

31. (675-58-133) OPERATION 1 & 2 :
OPERATION 3 :
31

32. OPERATION 4:
32

33. 33

34. OPERATION 5:
4.1 Demonstrating fixture design in CAD:
• The following fixture design can satisfy all the 5 operations on the work job and
can significantly reduce the required man-hours. The total diameter of the fixture
is 800mm and the thickness of the base plate is 100mm.
• Below is the demostration of operations which have to be performed to get the
required job according to the process chart
34

35. Job Operation 1
Job Operation 2
35

36. • FIXTURE THICKNESS DIMENTIONS
36

37. CLAMPS DEMONSTRATION
A total of 12 Clamps are located on the fixture. 6 are designated as outside and 6 as
inside clamps for various operations. Although lower race ring has comparatively less use
of outer clamps through-out the operations to complete the job. Clamps are located on 60
degrees with reference to centre point making a total of 360 degrees and an array of 6
clamps on each set.
37

38. 38

39. 4.2 CNC Programming Guide Codes
G-Codes simple definition
G00 Rapid traverse
G01 Linear interpolation with feedrate
G02 Circular interpolation (clockwise)
G03 Circular interpolation (counter clockwise)
G2/G3 Helical interpolation
G04 Dwell time in milliseconds
G05 Spline definition
G06 Spline interpolation
G07 Tangential circular interpolation / Helix interpolation / Polygon
interpolation / Feedrate interpolation
G08 Ramping function at block transition / Look ahead "off"
G09 No ramping function at block transition / Look ahead "on"
G10 Stop dynamic block preprocessing
G11 Stop interpolation during block preprocessing
G12 Circular interpolation (cw) with radius
G13 Circular interpolation (ccw) with radius
G14 Polar coordinate programming, absolute
G15 Polar coordinate programming, relative
G16 Definition of the pole point of the polar coordinate system
G17 Selection of the X, Y plane
G18 Selection of the Z, X plane
G19 Selection of the Y, Z plane
G20 Selection of a freely definable plane
G21 Parallel axes "on"
G22 Parallel axes "off"
G24 Safe zone programming; lower limit values
G25 Safe zone programming; upper limit values
G26 Safe zone programming "off"
39

40. G27 Safe zone programming "on"
G33 Thread cutting with constant pitch
G34 Thread cutting with dynamic pitch
G35 Oscillation configuration
G38 Mirror imaging "on"
G39 Mirror imaging "off"
G40 Path compensations "off"
G41 Path compensation left of the work piece contour
G42 Path compensation right of the work piece contour
G43 Path compensation left of the work piece contour with altered approach
G44 Path compensation right of the work piece contour with altered approach
G50 Scaling
G51 Part rotation; programming in degrees
G52 Part rotation; programming in radians
G53 Zero offset off
G54 Zero offset #1
G55 Zero offset #2
G56 Zero offset #3
G57 Zero offset #4
G58 Zero offset #5
G59 Zero offset #6
G63 Feed / spindle override not active
G66 Feed / spindle override active
G70 Inch format active
G71 Metric format active
G72 Interpolation with precision stop "off"
G73 Interpolation with precision stop "on"
G74 Move to home position
G75 Curvature function activation
G76 Curvature acceleration limit
40

41. G78 Normalcy function "on" (rotational axis orientation)
G79 Normalcy function "off"
G80 - G89 for milling applications:
G80 Canned cycle "off"
G81 Drilling to final depth canned cycle
G82 Spot facing with dwell time canned cycle
G83 Deep hole drilling canned cycle
G84 Tapping or Thread cutting with balanced chuck canned cycle
G85 Reaming canned cycle
G86 Boring canned cycle
G87 Reaming with measuring stop canned cycle
G88 Boring with spindle stop canned cycle
G89 Boring with intermediate stop canned cycle
G81 - G88 for cylindrical grinding applications:
G81 Reciprocation without plunge
G82 Incremental face grinding
G83 Incremental plunge grinding
G84 Multi-pass face grinding
G85 Multi-pass diameter grinding
G86 Shoulder grinding
G87 Shoulder grinding with face plunge
G88 Shoulder grinding with diameter plunge
G90 Absolute programming
G91 Incremental programming
G92 Position preset
G93 Constant tool circumference velocity "on" (grinding wheel)
G94 Feed in mm / min (or inch / min)
G95 Feed per revolution (mm / rev or inch / rev)
G96 Constant cutting speed "on"
G97 Constant cutting speed "off"
41

42. G98 Positioning axis signal to PLC
G99 Axis offset
G100 Polar transformation "off"
G101 Polar transformation "on"
G102 Cylinder barrel transformation "on"; cartesian coordinate system
G103 Cylinder barrel transformation "on," with real-time-radius compensation
(RRC)
G104 Cylinder barrel transformation with center line migration (CLM) and
RRC
G105 Polar transformation "on" with polar axis selections
G106 Cylinder barrel transformation "on" polar-/cylinder-coordinates
G107 Cylinder barrel transformation "on" polar-/cylinder-coordinates with RRC
G108 Cylinder barrel transformation polar-/cylinder-coordinates with CLM and
RRC
G109 Axis transformation programming of the tool depth
G110 Power control axis selection/channel 1
G111 Power control pre-selection V1, F1, T1/channel 1 (Voltage, Frequency,
Time)
G112 Power control pre-selection V2, F2, T2/channel 1
G113 Power control pre-selection V3, F3, T3/channel 1
G114 Power control pre-selection T4/channel 1
G115 Power control pre-selection T5/channel 1
G116 Power control pre-selection T6/pulsing output
G117 Power control pre-selection T7/pulsing output
G120 Axis transformation; orientation changing of the linear interpolation rotary
axis
G121 Axis transformation; orientation change in a plane
G125 Electronic gear box; plain teeth
G126 Electronic gear box; helical gearing, axial
G127 Electronic gear box; helical gearing, tangential
G128 Electronic gear box; helical gearing, diagonal
42

43. G130 Axis transformation; programming of the type of the orientation change
G131 Axis transformation; programming of the type of the orientation change
G132 Axis transformation; programming of the type of the orientation change
G133 Zero lag thread cutting "on"
G134 Zero lag thread cutting "off"
G140 Axis transformation; orientation designation work piece fixed coordinates
G141 Axis transformation; orientation designation active coordinates
G160 ART activation
G161 ART learning function for velocity factors "on"
G162 ART learning function deactivation
G163 ART learning function for acceleration factors
G164 ART learning function for acceleration changing
G165 Command filter "on"
G166 Command filter "off"
G170 Digital measuring signals; block transfer with hard stop
G171 Digital measuring signals; block transfer without hard stop
G172 Digital measuring signals; block transfer with smooth stop
G175 SERCOS-identification number "write"
G176 SERCOS-identification number "read"
G180 Axis transformation "off"
G181 Axis transformation "on" with not rotated coordinate system
G182 Axis transformation "on" with rotated / displaced coordinate system
G183 Axis transformation; definition of the coordinate system
G184 Axis transformation; programming tool dimensions
G186 Look ahead; corner acceleration; circle tolerance
G188 Activation of the positioning axes
G190 Diameter programming deactivation
G191 Diameter programming "on" and display of the contact point
G192 Diameter programming; only display contact point diameter
G193 Diameter programming; only display contact point actual axes center point
G200 Corner smoothing "off"
43

44. G201 Corner smoothing "on" with defined radius
G202 Corner smoothing "on" with defined corner tolerance
G203 Corner smoothing with defined radius up to maximum tolerance
G210 Power control axis selection/Channel 2
G211 Power control pre-selection V1, F1, T1/Channel 2
G212 Power control pre-selection V2, F2, T2/Channel 2
G213 Power control pre-selection V3, F3, T3/Channel 2
G214 Power control pre-selection T4/Channel 2
G215 Power control pre-selection T5/Channel 2
G216 Power control pre-selection T6/pulsing output/Channel 2
G217 Power control pre-selection T7/pulsing output/Channel 2
G220 Angled wheel transformation "off"
G221 Angled wheel transformation "on"
G222 Angled wheel transformation "on" but angled wheel moves before others
G223 Angled wheel transformation "on" but angled wheel moves after others
G265 Distance regulation – axis selection
G270 Turning finishing cycle
G271 Stock removal in turning
G272 Stock removal in facing
G274 Peck finishing cycle
G275 Outer diameter / internal diameter turning cycle
G276 Multiple pass threading cycle
G310 Power control axes selection /channel 3
G311 Power control pre-selection V1, F1, T1/channel 3
G312 Power control pre-selection V2, F2, T2/channel 3
G313 Power control pre-selection V3, F3, T3/channel 3
G314 Power control pre-selection T4/channel 3
G315 Power control pre-selection T5/channel 3
G316 Power control pre-selection T6/pulsing output/Channel 3
G317 Power control pre-selection T7/pulsing output/Channel 3
44

45. Note that some of the above G-codes are not standard. Specific control features, such as
laser power control, enable those optional codes.
45

46. M codes simple definition
M43 Spindle gear transmission step 3
M44 Spindle gear transmission step 4
M45 Spindle gear transmission step 5
M46 Spindle gear transmission step 6
M70 Spline definition, beginning and end curve 0
M71 Spline definition, beginning tangential, end curve 0
M72 Spline definition, beginning curve 0, end tangential
M73 Spline definition, beginning and end tangential
M80 Delete rest of distance using probe function, from axis measuring input
M81 Drive On application block (resynchronize axis position via PLC signal
during the block)
M101-M108 Turn off fast output byte bit 1 (to 8)
M109 Turn off all (8) bits in the fast output byte
M111-M118 Turn on fast output byte bit 1 (to 8)
M121-M128 Pulsate (on/off) fast output byte bit 1 (to 8)
M140 Distance regulation “on” (configured by G265)
M141 Distance regulation “off”
M150 Delete rest of distance using probe function, for a probe input (one of 16,
M151-M168)
M151-M158 Digital input byte 1 bit 1 (to bit 8) is the active probe input
M159 PLC cannot define the bit mask for the probe inputs
M160 PLC can define the bit mask for the probe inputs (up to 16)
M161-M168 Digital input byte 2 bit 1 (to bit 8) is the active probe input
M170 Continue the block processing look ahead of the part program (cancel the
M171)
M171 Stop the block processing look ahead of the probe input part program
segment (like a G10)
M200 Activate the handwheel operation in the automatic mode (to introduce an
offset in the program)
M201-M208 Select the axis (by number from 1 to 8) for the handwheel
46

47. operation
M209 Activate the handwheel operation in the automatic mode, with PLC
control of the axis selection
M210 Deactivate the handwheel input while in the automatic mode
M211 Deactivate this handwheel feature and also remove the handwheel offset
(if any)
M213 Spindle 2 clockwise
M214 Spindle 2 counterclockwise
M215 Spindle 2 stop
M280 Switchable spindle/rotary axis, rotary axis on, first combination
M281 Switchable spindle/rotary axis, rotary axis on, second combination
M290 Switchable spindle/rotary axis, spindle enabled, first combination
M291 Switchable spindle/rotary axis, spindle enabled, second combination
Note: Other machine functions, like tool change (usually M06) or coolant control, have
their M-code value specified by the PLC application not by the CNC software. Most of
the M-code values in above list are configurable.
Other M-codes (up to M699) can be handled by the PLC application based on the
particular machine requirements.
47

48. 4.2 SAMPLE CNC VTL PROGRAMMING
N5 MSG;COMPONENT NAME LOWER RACE RING
N10 MSG; MOUNT ON FACE DIA 736/ DIA 608 AND CLAMP ON OD
N15 MSG;AKE X CENTRE FOR DIA AND Z ON GEAR TOPFACE ZERO
N20 MSG;PROGRAMME MADE ON 2/4/16
N25 $P_UIFR[2]=CTRANS(X,0,Z,167.4)
N30 $P_UIFR[3]=CTRANS(X,-0.15,Z,73)
N35 $P_UIFR[4]=CTRANS(X,-0.15,Z,99.6)
;N40 M0; CHECK WORK OFFSETS
N45 G0 G53 G90 G97 X800 Z500 M5
;N45 GOTOF N465
N50 T3
N55 L950; (PCLNR 40X40 ID/FACING TOOL)
N60 M71; (TURNNING MODE)
N65 G18 G90 G95
N70 G55
N75 DIAMON
N80 G0 X580 M3 S120 D2
N85 Z50
N90 R10=2
48

49. N95 TRANS Z6
N100 PGR:
N105 G1 X580 F10
N110 G1 Z=-R10 F10
N115 X604 F0.4 M8
N120 Z2 F10
N125 R10=R10+2
N130 IF R10>6 GOTOF PSR
N135 IF R10<=6 GOTOB PGR
N140 PSR:
N145 G0 Z50 M9
N150 TRANS Z0
N155 M71; (TURNNING MODE)
N160 G18 G90 G95
N165 G55
N170 DIAMON
N175 G0 X580 M3 S120 D2
N180 Z5
N190 R10=2
N195 PGR:
N200 G1 X580 F10
49

50. N205 G1 Z=-R10 F10
N210 X618 F0.4 M8
N215 Z2 F10
N220 R10=R10+2
N225 IF R10>10 GOTOF PSR
N230 IF R10<=10 GOTOB PGR
N235 PSR:
N240 G0 Z50 M9
N245 TRANS Z0
N250 G55
N255 DIAMON
N260 G0 X625 M3 S120 D2
N265 G1 Z2 F5
N270 G1 X618 Z-1.5 F0.3 M8
N275 X615 F10
N280 Z2
N285 G1 X628 Z2
N290 G1 X618 Z-3 F0.3
N295 X615 F10
N300 Z2
N305 G1 X631.5 Z1 F10 M3 S120 D2
50

51. N310 X620.5 Z-4.5 F0.3 M8
N315 Z-10
N320 G1 X615 M9
N325 G0 Z500
N330 G0 G53 Z800 M5 D0
N335 T0
N340 L950
;N345 M0
N350 STOPRE
N355 G04 F10
N360 T8
N365 L951; (DRILL DIA 9 )
N370 M70; (MILLING MODE)
N375 G4 F5
N380 G18 G90 G94
N385 DIAMOF
N390 G57
N395 M2=3 S2=800
N400 G0 X300
N405 G0 Z50 D1
N410 G1 C0 F500
51

52. N415 R10=31.953
N420 L401
N425 R10=48.047
N430 L401
N435 R10=261.953
N440 L401
N445 R10=278.047
N450 L401
N455 G0 Z500 M9
N460 G0 G53 D0 Z800 M2=5
;N435 M0
N465 T16
N470 L951; (DRULL DIA 7 )
N475 M70; (MILLING MODE)
N480 G4 F5
N485 G18 G90 G94
N490 DIAMOF
N495 G56
N500 M2=3 S2=1000
N505 G0 X300
N510 G0 Z50 D1
52

53. N515 G1 C0 F500
N520 R10=0
N525 L401
N530 R10=60
N535 L401
N540 R10=90
N545 L401
N550 R10=120
N555 L401
N560 R10=150
N565 L401
N570 R10=180
N575 L401
N580 R10=213
N585 L401 M30
53

54. Chapter- 5
Conclusion
This report has discussed the development of a new fixture design for BMP-2 Lower
Race Ring. The objectives of this Project were to develop the necessary fixture design in
order to submit the blue-print in the casting section for its production and a job Process
chart along with the CNC programming to produce a good finish Lower Race Ring in
significantly less man-hours. [project summary and goals] Both objectives were met. By
manufacturing the above mentioned fixture for the job was able to successfully execute a
better finish Lower Race Ring in less than 1 hour. [significance of project] This was a
live project and provided hands-on experience on the CAD modeling, Casting processes
& successfully executing/ learning CNC program on a Brand new CNC VTL machine
from Hindustan Machine Tools (HMT) . The CNC Guide codes have been provided
along with the report in chapter- 4 as a reference to the correction of sample codes in case
any errors show up.
54