1. Slemani Polytechnic University
Slemani Technical Institute
Department Of Mechanic CAD-CAM
Practical training
Prepare by:
Rawa Esmail Muhamadamin
Supervisors:
Danar Esmail
Sherzad Abdullah
2021-2022
3. 1
Objectives
• Obtaining an information about CNC machines practically.
• Working in Reber Group Company (K Door) for 8 weeks.
• Learning to operate advanced CNC machines in Reber Group
Company (K Door).
• Improve self-skills of CNC machines.
• Applying theorical knowledges on CNC machines.
Introduction
Rebar Group Company is a massive expert door manufacturing
company, founded in 2013 by Reber Rasul Hamad.
Before 2013, it was just a common and regular factory, worked on the field
producing countertops and cupboards.
But after 2013, Rebar developed his business, establishing a company
capable of employing about 150 people.
Because the company was the right place for the knowledge we had gained
during our two years at the institute study, we chose it for an 8-week practical
training.
When talking about our practical training, we have tried to talk about the
most obvious things we have done, because the same things were repeated
most of the weeks. Therefore, when discussing our activities, we have
divided them into weeks, each week has two or less.
4. 2
Practical training schedule
• First week
In the first week, we archived a general information about the concept
of the company and how to work and produce the kinds of doors that are
being built in this company.
The first step of their work is manufacturing the inside layer of doors called
Extruded Polystyrene (XPS) foam bord.
The second step is manufacturing the outside layers of the doors which
consists of a plastic material, and this will be shaped with heat pressing
machine according to the desired decor.
Outside layer
(Plastic)
Inside layer
(XPS)
Outside layer
(Plastic)
5. 3
The doors are made with different sizes:
Standard size:
• 90cm×203cm
Custom sizes:
• 75cm×210cm
• 90cm×209cm
90cm×203cm 75cm×210cm 90cm×209cm
6. 4
There is a Turkish CNC milling machine to machining the XPSs according
to the desired decors, the CNC machine model is RJ-1325C, a qualified
engineer is working on this.
This machine can be controlled with a controller, which all commands are
stored in that controller, such as selecting files, as well as operating the
machine manually.
After machining the XPSs, there is a lot of residuals, if this residual is thrown
away, it will cause a huge loss of revenue, so the company has created a
recycling department to reuse all the residuals there.
Controller
7. 5
• Second week
In the second week, we knew the programs that are being used in
preparing decorate files to machining the XPSs.
There are some primary programs to preparing the tasks, CorelDraw 2018,
ArtCAM 2008, ArtCAM 2018 and AutoCAD 2017.
And there are some secondary programs, Vector Magic and Photoshop CC
2020.
• CorelDraw 2018: It is used to drawing the door decorates, and
AutoCAD 2017 is used to the same purpose.
• ArtCAM 2008: It is used to generating the decorate files to G&M
codes according to the CNC machine system.
• ArtCAM 2018: It is used to some special tasks as 3D machining on
Aluminum block, that used in manufacturing the outside layers of
the doors which consists of a plastic material.
• Vector Magic: It is used to enhancing and increasing an image
quality and it can generate an image to DXF file.
• Photoshop CC 2020: It is used to advertisements of the doors;
advertisement is one of the most important parts of any company.
8. 6
• Third week
In the third week, we used the programs and the machines together.
Some decorate files are created with CorelDraw and AutoCAD, then it
generated to G&M codes with ArtCAM 2008, after that the required file is
prepared, then the XPSs are machined with the CNC milling machine
according to the decorate files.
Also in the third week, an Aluminum block is machined, with a Chinese
CNC milling machine, the machine model is BCM1325C.
The work of this block of Aluminum is to give shape to the outside layers of
the doors with heat press machine.
9. 7
After making the door pattern, several
holes are made in the patterns, so that
air can easily pass through the holes
during pressure due to heat and the
decoration on the plastic piece looks
better.
In the same way as the XPSs, the
Aluminum residual is collected and
recycled in the recycling section to
reuse that later, because not wasting
the residuals is an important part of the
work.
10. 8
• Fourth week
After three weeks of learning about the operation of the CNC machine,
in the fourth week we were able to operate the CNC machine as an operator,
which included placing the XPSs in their proper places, changing and
selecting the suitable cutter tool, choosing the decorate files in the controller
program to machining the XPSs with a specific pattern.
Then we installed and assembled the
three layers of the door, then sent them
to a department called the pressing
department, to press the three layers of
the door, then the doors are prepared
for installation of door keys by drilling
and cutting the sides of the doors.
Finally, the doors are framed and after
that they are sent to the storage
department.
11. 9
• Fifth week
In the fifth week, we created some doors with custom sizes at the
request of a company.
The doors are created with size (75cm×210cm).
For this purpose, the decorate design is adapted with the size of the doors.
Basically, they don't work much on custom sizes, because they don't have
enough experts to modify the decorate, but because of the large number of
doors requested, they have to make them.
• Sixth week
In the sixth week, the manufactured doors are inspected, the doors with
failure were isolated.
The outside layers are shaped by heat
due to heat press machine, temperatures
also affect them, doors are often
damaged due to the high temperature of
the place where they are stored.
After the inspection, the doors are repaired by removing a side or both side
of the outside layers, then new layers are applied. And the removed side will
sent to recycling section to reuse it later.
12. 10
• Seventh week
In the seventh week, we repeated the work of the previous weeks,
preparing the parts and using the CNC machines and preparing a large
number of XPS. The seventh week was like a review of all the work we had
done for six weeks. And it was like preparing for eighth week where we are
supposed to do an exam on the CNC machines and the work we have done
in the previous weeks.
• Eighth week
In the eighth week, which was the final week, we conducted an exam,
which consisted of theoretical question and practical activities.
The theoretical questions included the following:
1. What does CNC mean?
(Computer Numerical Control)
2. What is the standard size of the doors?
(90cm×203cm)
3. What was the measurement of the cutters?
(They used 3,5,7,8 mm cutters)
4. What kind of toolpath does the cutter work on?
(They used machine along vector)
5. What are the Aluminum blocks used for?
(For shaping the outside layers of the doors)
13. 11
The practical activities included the following:
1. Selecting a decorate on the control of the machine.
2. Cutting tool change.
3. Change spindle speed and feed rate, when operating the machine
manually.
4. Operating the machine manually and machining some XPS.
5. Cleaning the Aluminum block from its residuals during machining.
