BY: B. NIKITHA(15911A03G9) SHALINI SINGH SOLANKI(15911A03L7)

1. MANUFACTURING OF MILLING
HEAD – ON KTM 760 BY USING
CNC PART PROGRAMING
BY:
B. NIKITHA(15911A03G9)
SHALINI SINGH
SOLANKI(15911A03L7)
INDEX
PAGE NO.
CHAPTER 1): HMT COMPANY PROFILE
1.1) HMT OBJECTIVES AND GOALS
CHAPTER 2): CNC SYSTEM
2.2) INTRODUCTION CNC
2.2) CONFIGURATION OF CNC SYSTEM
2.3) SPECIAL FEATURES OF CNC MACHINES
2.4) ADVANTAGES OF CNC
2.5) DISADVANTAGES OF CNC
CHAPTER 3): KTM HMC760
3.1) INTRODUCTION OF KTM-760(840D)
3.2) GENERAL SPECIFICATION OF THE KTM-760(840D)
3.3) INDEX TABLE
3.4) SPINDLE HEAD STOCK SPINDLE SPEEDS
3.5) PALLET SHUTTLE
3.6) PALLET TABLE
3.7) TOOL MAGAZINE
3.8) TOOL CHANGER ARM
3.9) X BED
3.10) UPRIGHT COLUMN

2. 3.11) Z-BED
3.12) ROTARY 4TH
AXIS
3.13) FEED TRANSMITTING
3.14) ELEMENTS
3.15) COOLANT
3.16) LUBRICATION
3.17) OILS USED AT VARIOUS PARTS IN HMT
PAGE NO.
3.18) COLLISION ZONES
3.19) MACHINE ZEROS
3.20) BENEFITS
3.21) APPLICATIONS
CHAPTER 4):
4.1) LOADING AND UNLOADING ARRANGEMENT
4.2) CLAPPING SYSTEM
CHAPTER 5): COMMON MACHINE OPERATIONS
5.1) MILLING
5.2) DRILLING
5.3) BORING
5.4) TAPING
CHAPTER 6): CNC PROGRAMMING
6.1) PROGRAMMING CONCEPT
6.2) INTERPOLATION
6.3) WORD TYPES USED IN CNC PROGRAM
6.4) G AND M CODES FOR KTM 840
CHAPTER 7): UNIVERSAL MILLING HEAD
7.1) INTRODUCTION TO UNIVERSAL MILLING HEAD (UMH)
7.2) WHY MILLING HEAD ATTACHMENT?
7.3) THE KEY SEQUENCE OF OPERATIONS
7.4) COMPONENT DRAWING

3. 7.5) PROCESS CARRIED OUT ON CNC MACHINE
7.6) PROCESS LAYOUT
7.7) CNC PART PROGRAMMING
7.8) THE UMH IMAGES
CONCLUSION
ABBREVIATIONS
CNC - Computer Numerical
PLC - Programmable Logic
VDU - Numerical Control
CPU - Central Processing Unit
HMC - Horizontal Machining
MDI - Manual Data Input
ISO - International
ATC - Automatic Tool Changer
RPM - Revolutions Per Minute
MRR - Metal Removal Rate
MDI - Manual Data Input
CAM - Computer Aided Manufacturing
DP - Depth
PCD - Pitch Circle Diameter
DIM - Dimension
LG - Length

4. CHAPTER 1
HMT COMPANY PROFILE
HMT was incorporated in 1953 by the Government of India as a machine tool
manufacturing company.
HMT machine tools play a key role in priority sector of the company such as
Railways, Defence Production, Shipping, Vehicle manufacturing, Heavy and Light
Engineering, Electronics, Electrical, Telecommunications and innumerable small scale
industries.
HMT manufactures all kinds of machines to meet any machine need; its range is
so wide that it extends from Turning, Milling, Gearing, Broaching and Metal Forming
machines to the latest CNC machines.
In 1953 OERWKON of Switzerland was HMT’s first collaborator. HMT soon
joined hands with several other world leaders in machine tools and precision engineering
to streamline its own technology and add on product lines.
Today the name HMT is synonymous with not only quality machine tools but also
with wristwatches, tractors, printing machines and other industrial products. HMT
comprises of 16 manufacturing units and 22 product divisions. HMT annual turnover is
US $ 230 millions (Rs.9300 millions).

5. The manufacturing facilities of HMT stretch from Srinagar to Kalamasary in
Kerala, the factory premises are in Bangalore, Pinjorre, Kalamasary, Hyderabad and
Ajmer. HMTwas established in 1965 in Bangalore, Hyderabad.
HMT Hyderabad Unit (Machine Tool Division):
HMT Hyderabad, fifth in the chain of chain of machine tool factories built by HMT
Ltd. It is a multi-purpose organization. It was started in the year 1964 on an area 340
hectares on plot on the outskirts, Hyderabad.
> HMT, Hyderabad has supplied over 2000 SPM (Special Purpose Machines) in last 30
years.
• HMT, Hyderabad manufactures following major type of SPM’s for Aluminum / Cast
Iron / steel machines.
• Way types SPM’s
• Dial type SPM’s
• Continuous rotary milling machines.
• Transfer lines.
• FMS
• HMT, Hyderabad as an employee strength of 1523 which includes 300 Engineers and
70 Design Engineers.
Various Departments in HMT:
• Production Department
• Tool Room
• Maintenance
• Stores
• Personal Department
• Material Department
• Production, Planning and Control Department
• Technical Training Centre

6. • Quality Control
1.1) OBJECTIVES & GOALS:
I OBJECTIVES:
1. Growth in terms of volume and volume added to absorb increase in operating costs
to maintain stable prices and render services to customers and to improve its market
share.
2. To export its product to earn foreign exchange so that each of its business unit is at
least a net exporter.
3. Import substitution of materials, components and know how to achieve self reliance.
4. Adequate return on capital employed for the survival and continuity of business to
fulfill its responsibilities to share holders.
5. Self-reliance to produce technology to meet new products, new market needs and to
improve its competitiveness.
GOALS
• To realize the above objectives the following performance goals have set S by the
company:
1. To maintain an annual growth of 10% sales.
2. To maintain growth in earnings subjected to maintain return of 16.6% a, on capital
employed.
3. To pay 10% dividend to its shareholders from cash-surplus available after meeting
its expenditure.
4. To reach an export target of 20% of production.
5. To improve R & D setting aside 2% of its returns.
6. To achieve substitution of improved materials and components by 5% per annum.
HMT - Hyderabad has the fo1lowing collaborations
1. Horizontal Boring Machines- Pegard, Belgium
2. Bed Type Milling Machines- Fritz Werner
3. Horizontal Machining Centre’s- KTM, UK

7. 4. Lamp Making Machines- Tungstram
HMT — Hyderabad especially manufactures 5PM units:
Special Purpose Machines (SPMs):
A SPM is a special purpose machine designed and built for carrying out the
particular machining operations on a particular component or components at an output rate
as required by the individual customer guaranteeing the consistency of performance.
HMT has, manufactured over 40,000 SPM’s for the last 30 years. Some of the features of
SPM are
• It is a component oriented machine.
• Build to ensure individual customer satisfaction.
• Results in boosted rate of output.
Production Facilities Available:
• Planning machines
• Ram type plane milling.
• Vertical Jig Boring Machine.
• Horizontal Jig Boring Machine.
• Floor type Horizontal Boring Machine.
• Slide way Grinding
• Universal Cylinder Grinding Machine.
• Surface Grinding Machine.
• Thread Grinding Machine.
• Molding Furnace.
• Induction Furnace
• Mould and Care Design Oven.

8. CHAPTER 2
CNC SYSTEM
2.1) INTRODUCTION TO CNC:
We have been designing machines that capable of manufacturing and machining
the various components required by the industry and caters to the needs of the common
man.
The printing press, the lathe, and numerous other machines were used in workshops
all around the world to meet this demand. But as technology improved, these once
indispensable machines are giving way to computer controlled machines that are not only
faster and accurate but also cheaper when large scale production in the term is
concentrated.
“Computer numerical control” is a microprocessor based system to store and
processes the data for control of slide motion and auxiliary functions of machine tools. NC
system is the vital part of CNC machine tools, which enable the operation of the various
machine members like spindle as per the sequence programmed into it depending on the
operations.
These features of the CNC machines have made them dispensable for the industry.
Today Computer Numerical Control (CNC) machines are found everywhere, from small
job shops in rural communities to Fortune 500 companies in large urban areas. Truly, there
is a facet of manufacturing that is not someway touched by what these innovative machines
can do. Everyone involved in the manufacturing environment should be well aware of
what is possible with these sophisticated machine tools.
The design engineer, for example, must possess enough knowledge of CNC to
perfect dimensioning and tolerance techniques for work pieces to be machined on CNC

9. machines. The tool engineering must understand CNC in order to design fixtures and
cutting tools for use with CNC machines. Quality control people should understand the
CNC machine tools used within the company in order to plans quality and statistical
process control accordingly. Production control should be abreast of their companys CNC
technology in order to make realistic production schedules. Managers, foremen and team
leaders should understand CNC well enough to communicate well enough with fellow
workers. And it goes without saying that CNC programmers, setup people operators, and
others working directly with the CNC equipment must have an extremely good
understanding of this technology.
2.2) CONFIGURATION OF CNC SYSTEM:-
A CNC System basically consists of the following: -
2.2.1) Central Processing Unit
2.2.2) Servo Control
2.2.3) Operator Control panel a
2.2.4) Machine control panel
2.2.5) Other peripheral devices
2.2.6 ) Programmable logic controller
2.2.1) CENTRAL PROCESSING UNIT:
Central processing Unit, the CPU, is the heart and brain of a CNC system. This
translates the part program stored in memory to position control signal signals. It also
oversees the movement of Control axis or spindle and whatever this does not match with
the program signal, a connective action of shutting down the machine.
Speed Control is also present in this CPU, which acts in unison with the CPU. This
checks whether machine tool axis movement is at the same speed as directed by the CPU.

10. 2.2.21 SERVO CONTROL:
This unit performs the data communication between the machine tool and the CPU.
Servo Control Unit receives the feedback Signals of the actual movement of the machine
tool slides from feedback devices like encodes, techno generators, etc. The movement of
the Slides is achieve through servo devices. The amount of movement of rate of movement
may be controlled by the CNC system depending on the type of feedback system used.
There are two types of systems, they are
1. Closed loop system
2. Open loop system
CLOSED LOOP SYSTEM:
Closed loop system is a system in which system, CNC system sends out command
for movement and the result is continuously monitored through various feedback devices.
There are generally two types of two type’s feedback requirements to a CNC system
namely Velocity feedback and an encoder or a linear scale is used for position feedback.
GENERAL BLOCK DIAGRAM OF CLOSED LOOP CONTROL SYSTEM*
VELOCITY FEEDBACK:
Techno generator for velocity feedback is connected to the motor rotates, thus
giving an analog O/p proportional to the speed of the motor. This analog voltage is taken
as the speed feedback by the servo controller and swift action is taken by the speed of the
motor within the required limits.

11. POSITION FEEDBACK:-
As the slide of the machine tool moves, it’s motion is feedback to the CNC system
for determining the position of the slide to decide how much is yet to be travelled and to
decide whether actual movement is as per the required rate, the system corrects its. If it
can’t then it initiates for disabling the drives and if necessary, it switches off the machine.
OPEN LOOP SYSTEM:
In this system, the CNC sends out signals for the movement but it does not check
whether actual movement is Talking place or not. Stopper motors are used for actual
moment and the electronics of this stopper motor is run on digital pulse from the CNC
system. As the system controllers have no access to know the system performance, they
can’t counteract. The disturbances appearing during the operation. They can be utilized in
point-to-point system, where loading torque on the Axial motors are low and almost
constant.
BLOCK DIAGRAM OF AN OPEN LOOP CONTROL SYSTEM:
Output is determined by the number of input pulses.
Since stepper motors are essentially digital actuators, there is no need to use digital to
analog and to digital converters in constructing digital control systems.
2.2.3) OPERATOR CONTROL PANEL:
Operator control panel provides the user interface to facilitate two-way
communication between user and the CNC system/machine tool. This consists of two parts
1. Video display unit
2. Key board
VIDEO DISPLAY UNIT (VPU):-
VDU displays the status of various parameters of the CNC system and machine
tool. It displays all current information such as
• Computer information of block currently being used.

12. • Actual position value, current feed rate, spindle speed.
LED’s are generally used to indicate important operating modes and status.
KEY BOARD:-
Key board is used for the following purpose
> Editing of programs, tool data machine parameters.
• Selection of different pages for viewing.
• Selection of different operating modes.
• Selection of feed rate over side and spindle speed over side.
• Execution of part programs
• Execution of other tool functions.
2.2.4) MACHINE CONTROL PANEL:
It is the direct interface between the operator and the NC system, enabling the
operation of machine through the CNC system.
2.2.5) OTHER PERIPHERALS:
These includes sensor interface provision for communication equipment,
programming units, printer, tape recorder etc.
2.2.6) PROGRAMMABLE LOGIC CONTOLLER PLC):
The PLC matches the NC to the machine. Basically PLC was introduced as
replacements for ‘a’ hardwired relay control panels. They were developed to be
reprogrammed without hardware changes when requirements were altered and thus they
are reusable. These PLC’s arc available with increased functions, more memory and longer
input/output capabilities.
The I/O structure is one of the major strengths of PLCs.
The inputs can be push buttons, limit switches, relay contacts, analog sensors,
proximity sensors, etc, the outputs can be motor starters, solenoid valves, relay coils, LED
displays, etc.
POWER SUPPLY FOR CNC MACHINES:

13. Indian standards for industrial power supply is based on 3 phase, 4 wire system,
i.e., 3 phase + earth at 425 VAC, 50 Cycles.
2.3) SPECIAL FEATURES OF CNC MACHINES:
In case of computers numerical control machine tools, a dedicated computer is used
to perform all the basic NC functions. The complete part programmer to produce a
component is input and stored in the computer memory and the information for each
operation is fed to the machine tools i.e., motors, etc, the part programmers’ can be stored
in the memory of the computers and used in future. The conventional NC machine tools
are not much in use these days. CNC machine tools are widely used due to many new
control features available on the machines. Some of the additional features available in
CNC machines tools are:
1) The part programme can be input to the controller unit through key J board or the
paper tape and can be read by the tape reader in the control j unit.
2) The part programme once entered into the computer memory can be used again and
again.
3) The part programme can be edited an optimized at the machine tool itself. It there is
any change in the design of the component, the part programme can be changed
according to the requirements.
4) The input information can be reduced to a great extent with the use of special sub-
programmes developed for repetitive machining sequence .For common operations
such as drilling holes on a pitch circle, special cycle programmes can be built and
stored in the computer memory. These sub programmes or subroutines can be
retained and used any number of time within a part programme.
5) The CNC machines have the facility for proving the part programme without actually
running it on the machine tool. The control system processes the part programme and
the movement of the cutting tool in each operation is shown on the monitor screen
(VDU).The shape of the component which will be produced after machining is also
shown on the screen without actual machining taking place.
6) CNC control unit allows compensation for any changes in the dimensions of the
cutting tool. When the part programmer is written, pad programmes has a particular
type and size of cutting tool in mind.CNC control system allows the compensation
to be made for difference between the programmed cutter and actual cutter used.

14. 7) With the CNC control systems, it is possible to obtain information on machine
utilization which is useful to the management. The control system can provide the
information such as number of components produced, time per component, time for
a setting up a job, time for which a particular tool has been in use.
2.4) ADVANTAGES OF CNC MACHINES:
1) Flexibility: Additional features can be added in the field. The modification or changes
in component design can be readily accommodated by reprogramming and altering the
concerned instruction.
2) Elimination of operator errors: the machine is controlled by program of instruction
stored in the memory of the computer, the program is checked before it goes to the machine
so no errors will occur in the job.
3) Lower labor cost: one Operator can run two or more machines.
4) Linger tool life: Tools can be used at optimum speeds and feeds because these functions
are controlled by the part program. Operator can change the speed &feed if the material
has different properties.
5) Less scrap: since the operator errors are eliminated a proven part program results in an
accurate component.
2.5) DISADVANTAGES:
1) Higher investment cost: CNC machine tools represent a more I sophisticated and
complex technology. This technology costs more to I buy than its non -CNC
counterpart, the higher cost requires manufacturing management to use these
machines more aggressively I than ordinary equipment. High machine utilization is
essential in I order to get reasonable returns on investments. Machine shops must
operate their CNC machines two or three shifts per day to to achieve this I high
utilization.
2) Costlier CNC personal: certain aspects of CNC machine operations required a higher
a skill level than conventional operations .part programming &CNC maintenance are
lack of skills areas. However, advantages of CNC machine outweigh the
disadvantages considerably & the CNC machine has been widely accepted by the
industry.

15. 3) Higher maintenance cost: because CNC is more complex technology & machines are
used harder, the maintenance problems become more acute.
CHAPTER 3
KTM HMC17601840D
3.1) INTRODUCTION TO KTM 760
OVERVIEW: -
The SINUMERIK 840D power line provides you with modularity, openness, a
uniform structure for operating, programming and visualizing and provides a system
platform with innovative functions for almost technologies. Together with the
SIMODRIVE611 digital converter system, and supplemented by the SIMATIC S7-300
automation system. The SINUMERIK 840D power line offers a complete digital system
which is especially suitable for complex processing tasks and is characterized by
maximum dynamics and precision, with the SINUMERIK 840D power line, certified
safety integrated function can be obtained with highly effective protection of persons and
machines is possible in a simple, economical practical manner.
KTM(760) 840D:
The KTM 840 machining centre is a CNC controlled horizontal spindle machining
center which consists of a machine control unit and a hydraulic power supply. It derived
its name from the fact that it can perform multiple operations like drilling, milling, turning
etc.
The machine offers three perpendicular motions with a rotary fourth axis. An
automatic pallet shuttle and automation tool charger for a tool magazine, which can
accommodate up to 40 tools, are some of its special features.

16. MACHINE SPECIFICATIONS [CNC-HMC]
TYPE OF MACHINE : CNC-HMC
MACHINE NUMBER : 494-02
MAKE : KTM 760
COUNTRY : UK
TABLE SIZE : 760 x 760mm
TABLE TRAVEL : X-axis 1300mm
VERTICAL TRAVEL Y : Y-axis 1000 mm
COLUMN TRAVEL : Z-axis 1000mm
SPINDLE TAPER : ISO 45
CO.ORD.ACCCURACY : + 0.013/300 L
PERMISSIBLE LOAD : 1800 KG

17. DESCRIPTION:
The tool transfer mechanism automatically transfers a selected tool from the tool
storage magazine to the park position in the swing arm at the side of the machine. The tool
change mechanism automatically exchanges the pre-selected tool in the swing arm park
position for the tool in the spindle.
The tool change time, only, is approximately 1 seconds, i.e., the time to exchange
the tool in the park position for the tool in the spindle. The maximum tool select, tool
transfer and e tool change time is approximately 25 seconds, i.e., to find the tool in the
magazine, transfer it to the swing arm and to change it in to the spindle.
TOOL SELECTON AND TOOL TRANSFER:
The machine uses the system of coded tool pockets. This system ensures that a
tool, when used, is always returned to the same pocket in the magazine. The random tool
selection feature is initiated by programming the appropriate information showing the
location of the tool in the tool magazine must first have been entered in to the CNC
memory of the control and the operator must have put the tool in to the correct pocket.
On reading the commanded T-word the following sequence is carried out:
• The swing arm comes round to the park position beside the tool magazine if it is not
already at this position.
• If there is already a tool in the swing arm it is transferred out and replaced in the
magazine pocket from which it originally came.
• The magazine rotates to find the pocket containing the tool called for.
• The tool is transferred out of the magazine and in to the swing arm. The swings are
then stays parked adjacent to the magazine until an M06 tool transfer command is
read.

18. ZERO REFERENCE POSITIONS:
All axes movements in positioning mode are measured with respect to the fixed
reference position which is retained by the control. At these positions, the following
dimensional relationships exist in each axis:
• *x’ Axis= 0000.000 when the table centerline is 650mm (25.5905”) to the right of
the spindle centerline looking away from the spindle.
• y’ Axis= 0000.00 when the spindle centerline is 75mm (2.9527”) above the table
surface.
• ‘z’ Axis =0000.000 when the spindle is I85mm(7.2835”) from the table centre
rotation.
• ‘B, Axis = 000.000 when the table tee slots are parallel to the X axis and the datum
edge (with the two edge locators) is to the machine (away from the spindle)
FEED RATES:
• X,Y and Z axes : 1.0 to l0,000mm/min
• Index table : 4 rev/mm
• Rotary table : 1.0 to 1 1,520mm/mm (at a 458,32mm radius)
• Manual override (in l0% increments): 0 to 120% (upto lOin/mm max. linear).
• Thrust on linear axes : upto 17500 newtons (400/ft) max.
SPINDLE:
• Speed range (in I rev/mm increments) : 20 to 3600 rev mm
• Tapping range : 20-1000 rev mm
• Horsepower : 20 hp/15 kw from 200rev/mm upwards

19. AUTOMATIC TOOL CHANGER AND MAGAZINE:
• Tool identification : Coded tool pockets
• Selection : Random
• Tool length : 400mm max.
• Tool weight : 15 kg maximum (33 Ib)
• Capacity : 40 tool storage
• Tool size : 160mm fla Il dia. Max.
IMAGE
TABLE:
• Overall table work surface :760x760mm rounded to 1000mm dia.
• Maximum overall table load :1800 kg (4000 Ib)
• Index table positions :360-1° increments or 144-21/2° increments
• Edge locators to table centerline :380, 00mm( 14,9606”)
• The edge locating surfaces of the table are held to within .013mm TIR (Total
Indicator Reading) with respect to the table centerline. Accuracy (At established
temperature of 22°c)
• Absolute individual slide positioning accuracy - + 0.025mm
• All linear axes-over full travel: •+ 5 seconds Indexing.
> Individual slide repeatability
All linear axes : + 0.005mm.
> Indexing : + 2.5 seconds.

20. ALIGNMENTS:
• Individual linear axis motions over full travel with respect
• To table location surface and to one another -
Maximum : 0.025mm
Minimum : 75mm
Maximum : 1075mm
Center of table rotation to spindle taper gauge line (z Axis)
Minimum : 185mm
Maximum : 1185mm
Center line of table rotation to centerline of spindle (x axis)
Minimum : 0
Maximum : 1300mm
LUBRICATION OIL USED AT VARIOUS PARTS IN HMT:
• Head stock SERVO SYSTEM 68
• Hydraulic power pack SERVO SYSTEM 68
• Auto lube system SERVO SYSTEM 68
•Tool magazine, lift shaft bushes SERVO SYSTEM 3
•Air lubricator SERVO SYSTEM 32
TOOL CHANGER ARM:
It is mounted on a swing arm unit mounted on the left hand side of the column.
Tools are transferred from drum to parked position on a swing arm unit, which is then
swung through 900 to the tool change position by a hydraulic cylinder. The normal cycle

21. will be that the next tool will be selected and transferred to perk position while machining
is in the progress with current tool the swing aim will be through 900 whilst the head is
returning in the tool change position.
The double ended tool change arm is actuated by a simple mechanism trigged by
hydraulic power, which can changes tool weighting up to 20kg. tool are held firmly in the
ends of the arm by locating in the deep groove in the tool holder flange.
SPINDLE HEADSTOCK AND SPEEDS:
The spindle is housed in spindle headstock and is driven by DC motor through a
three speed gear box. Head stock forms the basis for Y axis motion. Spindle speed from
20 to 3600 rpm are provided in I rpm increments. A tapping range from 20 to 1000 rpm is
provided in 1 rpm e increments .the spindle gear box is lubricated from a 6 liters oil sump
mounted under the head. The gear selection for obtaining various speeds is done with
hydraulic cylinder.
SPINDLE:
A 20hp DC motor powers the spindle, the spindle is arranged for 45 | international
taper with a claw type tool retention device that is spring clamped and hydraulically
unclamped.
Spindle bore : 100mm
Drive : DC electric motor
Speed range Width : 0-100%
Length of slice : 150mm
PALLET SHUTTLE:
The pallet shuttle feature gives the facility to change the table pallet automatically
and rapidly, which reduce down time such as work piece loading to give and work holding
feature changeover as this can be carried out when machine is in cycle. These pallets are
mounted on individual wing bases hydraulic motors mounted under these wing bases
controls the motions.

22. The automatic work piece changing by removable pallet system can be I applied
to either index or rotary table. Pallets are automatically transported i on and off the table
saddle park station by the use of as conveyor chain, the park station are affixed at 90 to
the front along X axis bed at opposite ends.
Pallets are located automatically on the table saddle through the use of four
precision, male and female cones and hydraulic clamped and de-clamping. Additional
pallet may be provided but two are supplied as standard. Pneumatic cylinder controls the
door opening on the pallet shuttle. 760X760 mm*mm 1800 kg 38 seconds.
PALLET TABLE:
Size : 760x760 mm x mm
Max component weight : 1800kg
Minimum pallet change : 38 seconds
X Bed:
The X bed is a mild steel fabrication which carries hardened and ground steel ways
to form the X axis. Both ends of the bed have covers fitted to keep scarf and coolant from
the ball screw currently these covers easily removable for access.
UPRIGHT COLUMN:
The bifurcated column is a mild steel box ribbed with fabrication Facings are
provided on front face to take hardened and ground steel ways to form Y axis slide for
head stock. The Y -axis drive motor and hydraulic counter balance ore mounted on top of
column is formed to take Z-axis slide hearings.
Re-circulating roller bearings are used to take the weight and for pre loading and
damping. The control valves for the 40
Z-BED:
It is mild steel, fabrication canying hardened and ground steel ways to form the Z
-axis. The axis drive is situated in central well.
Material MS fabricated

23. Cross -sectional width 865 mm
COLLISION ZONES:
The collision zone is an area in which the spindle nose and/or the Y - axis roller
can collide with the table surface, the table edge locators or the pallet hook on machines
with the pallet shuttle feature. To avoid this, the programmer must be aware of the
following criteria, (that is coordinates taken are absolute values taken from machine zero).
The standard collision zones stated are only approximate and should be) referred
to only as a general guide. The figures stated in specifications are to safe guard extreme
conditions. These parameters may be infringed under certain circumstances at the
programmer’s discretion.
COOLANT:
The machine is providing with a freestanding 150 liters coolant tank situated at the
end of the X-axis bed. Coolant is pumped to the spindle nose and is emitted through two
nozzles, adjustable for flow and direction. The coolants are used in order to safe guard the
tools, components from elongation, for smooth machining and to retain hardness at higher
temperatures.
FEED TRANSMITTING ELEMENTS:
Ball screw (anti friction elements) act as fed transmitting elements which work with an
efficiency of 96%.
Using all screw list motion can be controlled to maximum extent lead screws (friction
elements) are purged because of their efficiency 40% slip- stick.
Motion and their inability to control positioning accuracies.
ROTARY 4TH AXIS:

24. The 4th
axis position rotary able is mounted on the table and is driven by a D.C motor via
a worm wheel arrangement.
PRAMETERS:
CYCLE 81(RTP, RFP, SDIS, DP, DPR)
CYCLE 82(RTP, REP, SDIS, DP. DPR, DTB)
CYCLE83 (RTP, REP, SDIS, DP, DPR, FDEP, FDPR, DAM, DTB, DTS, I IFRF,
VARI)
CYCLE84 (RTP, RFP, SDJS, DP, DPR, DTB, SDAC, MPIT, PIT, P055, SST,SSTI)
CYCLE840 (RTP, RFP, SDIS, DP, DPR, DTB, SDR, SDAC, ENC, MPIT, PIT)
CYCLE85 (RTP, REP, SDIS, DP, DPR, DTB, FFR, RFF)
CYCLE86 (RTP, REP, SDIS, DP, DPR, DTB, SDIR, RPA, RPO, RPAP, P055)
CYCLE87 (RTP, REP, SDIS, DP, DPR, SD1R)
CYCLE88 (RTP, RFP, SDIS, DP, DPR, DTB, DTB, SDIR)
CYCLE89 (RTP, RFP, SDIS, DP, DPR, DTB)
RTP... RETRACTION PLANE
RFP... RFRENCE PLANE
SDIS... SAFETY CLEARENCE (ENTER WITH OUTSIGN)
DP... FINAL DRILLING DEPTH (APS)=R03
DPR...FINAL DRILLING DEPTH RELATIVE REFRENCE PLANE (WITH OUT
SIGN)
DTB... DWELLTIME AT FINAL DRILLING DEPT=R04
FDEP... FIRST DRILLING DEPTH (APS)
FDPR...FIRST DRILLING DEPTH RELATIVE REFRENCE PLANE (WITHOUT
SIGN)
DAM... AMOUNT OF DEGR.ESSION (ENTER WITHOUT SIGN)
DTS...DWELL TIME AT STARTING POINT AND FOR SWARE REMOVAL

25. FRF... FEED RATE FACTOR FOR FIRST DRILLING DEPTH (ENTER WITH
OUT SIGN, VALUE RANGE: 0.001-1)
VARI... TYPE OF MACHINE
CHIP BREAKING =0
SWARF REMOVAL=l
SDAC ... DIRECTION OF ROTATION OF END OF CYCLE
• MPIT... PITCH AS THREAD SIZE (WITH SIGN)
VALUE RANGE: 3... (FOR M3)…… 48(M48)
• THE SIGN DETERMINES OF DIRECTION OF ROTATION IN A THREAD
PIT….. PITCH AS VALUE (WITH SIGN)
VALUE RANGE: 0.001....2000.00mm)
THE SIGN DETERMINES DIRECTION OF ROTATION IN A THREAD
POSS.... SPINDLE PASITION FOR ORIENTED SOINDLE STOP TN THE
CYCLE (IN DEGREES)
• SST... SPEED FOR TAPPING
• SSTI... SPEED FOR RETRACTION
SDR...DIRECTION OF ROTATION FOR RETARCTION
|VALUE: 0(AUTOMATIC REVERSE DIRECTION OF ROTATION)3 OR 4(FOR M3
OR M4)
ENC... .TAPPING WITHOUT ENCODER
VALUES: 0 WITH ENCODER
: 1 WITHOUT ENCODER
FFR... FEED RATE R08
RFF.. ..RETARACTION FEED RATE R09
SDIR.... DIRECTION OF ROTATION

26. VALUE: 3(’FOR M3) R07 4 (FOR M4)
RPA... RETARCTION PLANE IN THE ABISCISSA OF THE ACTIVE
PLANE (INCRENMENTAL, ENTER WITH SIGN)
RPO...RETARCTION PATH IN ORDINATE OF THE ACTIVE PLANE
(INCREMAENTAL ENTER WITH SIGN)
RPAP...RETARCTIN PATH IN APPLICATE OF THE PLANE (INCREMENTAL i
ENTER WITH SIGN)
BENEFITS:
• The digital CNC system for complex tasks.
• Maximum performance and flexibility especially for complex multiple-axis
systems.
• Uniform openness from operation up to the NC core.
• Integral. certified safety function for man machine: SINUMERIK safety integrated.
• Well-proven operating and programming software such as manual turn, shop mill
or shop turn and Motion control information system products (MCIS products).
APPLICATION:
The SINUMERIK 840D power line is used worldwide for turning .drilling .milling
grinding, laser machining, nibbling, punching, in tool and mold making, as press control,
for high speed cutting applications, for wood and glass processing, for handling operations,
in transfer lines and rotary indexing machines, for mass production and job shop
production.
The 11 powerline is available as an export version for use in countries where
approval is required.

27. CHAPTER 4
STUDY OF THE LOADING AND UNLOADING ARRANGEMENTS
The design of the fixture should be such so as to enable the operator to fix up and
remove the components with ease, before and after machining without exerting
unnecessary effort and spending undue idle time, the way of un loading should be quick,
simple and positive.
STUDY OF THE CLAMPING ARRANGEMENTS:
The clamps serve the purpose of holding work pieces securely on the fixture against
the cutting forces. in order to achieve the most efficient clamping ,the operational factors
may be considered.
• The clamping pressure should be exerted on the solid supporting part of the work
to prevent distortion.
• The clamping pressure should be kept low. It should be sufficient to hold the work
against the cutting pressure.
• The movement of the clamp for loading and unloading purpose should be kept
limited
• The clamp should be simple and fool proof.
• The clamp should be sufficiently robust to prevent bending.
REQUIREMENTS OF THE CLAMPING SYSTEM:
The clamps must be positioned so that clamping forces act on supported or rigid
parts of the work piece as shown in fig ….. The reaction to the clamping and cutting forces
must be taken by the main frame of the fixture. Care must be taken to ensure that the
clamps can be operated in safely, as quickly as possible and with minimum effort on the
part of the operator. The clamps must not be loosened by the vibration caused by the
cutting action. The clamping forces must be regulated so that they are adequate, and yet
do not cause damage to the work piece, the force can be regulated by design of clamp.

28. When the force is exerted by hand nut, the size of the nut can be designed to give the
required force.
CHAPTER 5
COMMON MACHINING OPERATIONS
I. 5.1) MILLING:
Milling is a very fast method of manufacturing of cutting away material by feeding
a work piece past a rotting multiple tool cutter. The machined surface may be flat, angular,
or curved, the machine for holding the work piece, rotating the cutter, and feeding it is
known as the milling machine.
5.2) DRILLING:
Drilling is the most common process. One estimate is that 75% of metal cutting
material removed comes from drilling operations. Drilling involves the creations of the
holes that are right circular cylinders, this is J accomplished most typically by using a twist
drill the figure below J illustrates a cross section of a hole being cut by a common twist
drill. The chips must exist through flutes to the outside of the tool as can be 9 seen in the
figure, the cutting front is embedded within the work piece making cooling default thru
cutting area can be flooded, coolant spray mist I can be applied, or coolant delivered to the
drill bit.
Important angle for a typical twist drill bit:
Figure: Angle in a twist drill bit

29. SPOT DRILL:
Spotting drill are counter sinks for NC operations, they are ideal for close tolerance
NC spotting operations and provide a more accurate and faster spotting location for follow
–up drilling. Basically, it eliminates wandering.
Figure: Spot drill
5.31 BORING:
Boring is a process where an accurate internal cylindrical surface is produced by
enlarging an existing opening in the work piece moves parallel to the axis of rotation of
the cuffing tool as the work piece or boring bar advances, helical feed marks are produced
on the surface.
The tool used for accomplishing the boring process is known as a boring bar. A
boring bar is used in the cutting of an inner surface. It can make the hole, which has a big
diameter, which is needed an accurate diameter, and which needs a high surface roughness.
As shown in the figure, a single / multipoint cutting tool rotating in relation to the
work piece is used to accomplish boring. Movement of the boring bar for feeding is into
or out of the page.
Boring may generate May either an initial cylindrical surface or an internal I
tapered surface. Drilled hole, which is not properly, can be made concentric with the axis
of rotation of the spindle by boring, boring is also used for II manufacturing larger diameter
holes, since drills in larger are relatively expensive and not feasible for most applications.

30. Fig. Boring Fig. Boring operation
5.4) TAPPING:
Tapping is used to produce internal threads in previously drilled holes. A tap is a
multi-fluted cutting edges on each blade in the shape of threads. S it is a form-type cutter,
reciprocating the shape of its cutting edges in the work. Taps are made of either carbon
steel or high speed steel.
The most common hand taps are called taper, plug, and bottoming taps. All there
are identical expect for the bevel angle at the tip. The bevel at the tip serves two purposes:
it guides the tap in to the holes and it ramp cuts the Ii undeveloped first threads.
A hole is to be tapped is first drilled or bored to a diameter which will provides a
thread approximately 75% of the fill thread depth above 60 will not result in a sustainable
increase in the strength for the thread. However, 75% is usually is selected as a satisfactory
% of the full thread depth.
The nature of the tap makes it necessary for the tap to come out rotating in the
opposite direction as it is coming out of a hole.

31. CHAPTER 6
CNC PROGRAMMING
A CNC Program is a step by step set of coded instructions consisting of alphabet
letters, numbers and symbols in language, which the machine tool unit can understand.
The in these instructions represents the magnitude, speed and direction of the operative
units of the machine tool.
6.11 PROGRAMMING CONCEPT:
A Part program contains all the information for machining of components, which
is input the CNC system, The CNC system provides signals at correct sequence to various
S drive units of machine. The program is prepared by listing the coordinate values (X, Y
and Z) of entire tool paths as suited to machine the complete component. The coordinate
values arc I prefixed with preparative codes to indicate the type of moment (point to point,
straight or circle) from one coordinate to another. Also the coordinates are suffixed with
miscellaneous codes from initiating machine tool functions like start, slop and spindle
movement, coolant on/off and optional stop. In addition to these coded functions, spindle
speeds and feeds, the required tool numbers to perform machining in desired sequence are
also given. All these elements represent a line of formation and form on meaningful
command for machine to execute and are called a block of information. The number of
such blocks of a information written sequentially forms a part of the program for the
particular component.
DIFFERENT STEPS PREPARING A PART PROGRAM:
• Study the relative component drawing thoroughly.
• Identify the type of material to be machined.
• Determine the specifications and functional of machine to be used.
• Decide the dimension and mode, metric or inch
• Decide the coordinate system, absolute or incremental.
• Identify the place of cutting.
• Determine the cutting parameters for the job/tool combination.
• Decide the feed rate of programming-mm/mm or mm/rev.

32. • Check the tooling required
• Establish the sequence of matching operations.
• Identify whether use of special features like subroutines, mirror imaging etc. is
required or not.
• Decide the mode of storing the part program once it is completed.
ABSOLUTE VERSUS INCREMENTAL MOTION:
In the absolute mode, the end point for all motions will be specified from the
program zero point. In the incremental mode, end points for motions are specified from
the tools current position, not from program zero position, not from program zero. While
there are times when the incremental mode can be very helpful, generally, this is the more
cumbersome difficult method.
Difference between incremental and absolute mode
Command for defining the end point location will be:
G00X1O3YI08 (in absolute programming)
Advantages of using absolute mode are as follows:
• Easy to determine the current position for any command.
• If a motion mistake is made in one command of the program, only one movement will
be incorrect unlike in incremental mode.
6.2) INTERPOLATION:
LINEAR & CIRCULAR INTERPOLATION:
When both the axes are moving the control must perfectly synchronize the X and
Y axis movements to move along a perfectly straight line to get to the programmed end
point. Also, if machining is to occur during the motion, a motion rate must also be
specified. This requires linear interpolation.

33. Actual motion generated with linear interpolation. Notice the series of very tiny
single axis movements. The steps size is equal to the machine’s resolution, usually 0.0001
mm.
CIRCULAR INTERPOLATION:
In similar fashion, many applications for CNC machine tools require that the
machine be able to from circular motion. Application for circular motions include firming
radii on turned work pieces between faces and turns, and milling radii on contours on
machining centers. This kind of motion requires circular interpolation. As with linear
interpolation, the control will do its best generate as close to a circular path as possible
Fig. Linear Interpolation
+
LINEAR INTEPOLATION CIRCULAR TNTERPOLATION

34. 6.3) WORD TYPES USED IN CNC PROGRAM:
As stated, programs are made up of blocks and blocks are made up of words. A
block may contain any of the following:
• O-Program number (used for program identification)
• N-Sequence number(used for line identification)
• G -Preparatory function
• X – X-Axis designation
• Y – Y-Axis designation
• Z - Z - Axis designation
• R - Radius designation
• F - Feed rate designation
• S - Spindle speed design
• H - Tool length offset designation
• D - Tool length offset designation
• T - Tool designation
• R - Program parameter
• M - Miscellaneous functions
Block or sequence number (N):
A part program is constructed with a number of blocks. Block number represents
the operation number in usually the first character. The number of digits in a block number
depends upon the control manufacturing (usually it is 4 digit). Block numbers are mainly
used for the convenience of an operator in identifying the different operations. It can be
specified in the following manner.
Preparatory function (G):
These are the commands, which prepare the machine for different modes of
moments like positioning, contouring, thread cutting, etc.
DIMENSION WORDS:

35. A dimension word specifies a tool movement. It is composed of the address of the
axis to be moved and the value indicates the move direction and amount.here the basic
axes are addressed by using the letters X, Y, Z.
SPINDLE SPEED:
This may indicate either the spindle in rpm or cutting speed in m/min.
FEED RATE WORD:
The feed rate or the rate at which the cutter travels through the material is specified
in mm/min or mm/rev.
TOOL NUMBER (T):
For machines having automatic tool changes or turrets, the T-word calls out a
particular tool that has to be used for cutting.
D-WORD:
It indicates either the cutting radius and length compensations.
6.41 G AND M CODES FOR KTM 840:

36. PREPARATORY FUNCTIONS:
GOO Rapid traverse, coarse exact positioning
GOl Liner interpolation
GO2 Circular interpolation clockwise
GO3 Circular interpolation counters clockwise
GIO Polar coordinate programming rapid traverse
G11 Polar coordinate programming linear interpolation
G33 Thread cutting constant lead
G34 Thread cutting linearly progressive lead
G35 Thread cutting linearly depressive lead
G04 Dwell duration predetermined in seconds under
Address x or F and in resolutions under address
G09 Speed reduction, fine exact positioning
G16 Plane selection with freely selectable axes (rest as Per GI 7, machine datum)
G17 Plane selection X-Y
G18 Plane selection Z-X
G19 Plane selection Y-Z
G25 Max. Working area limitation
G26 Max. Working area limitation
G40 No cutter radius counters compensation
G41 Cutter radius counters compensation, counter Clock wise
G42 Cutter radius counters compensation, clock wise

37. G53 Suppression of zero offset
G54 Zero offset l
G55 Zero offset 2
G56 Zero offset 3
G57 Zero offset 4
G58 Programmable additive zero offset
G59 Programmable additive zero offset
G60 Speed reduction fine exact position
G62 Continuous path operation, block transition with Speed reduction
G63 Taping without encoder, 100% speed rate
G64 Continuous path operation, block transmission with Speed reduction
G70 Inch input system
G71 Metric input system
G90 Absolute dimensioning
G91 Incremented dimensioning
G92 Limitation of set spindle speed under address-S
G94 Feed rate under address-F in mm/mm or inches/m
G95 Feed rate under address-F in mm/rev or inches/rev
FIXED CYCLES:
G80 Delete G81 to G89
G81 Drilling cycle L81- drilling, centering
G82 Chip brake drilling cycle L82-drilling, spot facing
G83 Deep hole drilling cycle L83-deephole drilling
G84 Tapping cycle L84-thread tapping with encoder
G85 Reaming cycle boring L85-l
G86 Rough boring L86-boring2
G87 Finish cycle L87 boring3
G88 Back boring cycle L88-boring4
G89 Pre cycle L89-boring5
G90 Absolute programming
G91 Incremental programming
G94 Feed in mm/mm

38. G95 Feed in mm/rev
GENERAL FUNCTIONS:
A-Angle in degrees with contour definition
U-radius with circular interpolation
I-interpolation parameters for X-axis in mm/inches
(Or) Thread lead in mm/inches
J-interpolation parameters for y-axis in mm/inches
(Or) Thread lead in mm inches
K-interpolation parameters for Z-axis in mm/inches
(Or) Thread lead in mm/inches
D-selection of tool offset-DO
P-l to99 number of subroutine passes
R-0 to49 transfer parameters & 50 to 99 arithmetic parameters
F-feed rate in mm/mm dwell in seconds
S-spindle speed in rev/mm dwells in revolutions mm
T-toll number
H-auxiliary functions
L-sub routine number
MISCELLANIOUS (M) FUNCTIONS:
M00 programmed stop unconditional
M0l programmed stop conditional
M02 program end, in last program block
M17 subroutine end, in last subroutine block without stop in repeat pass
M30 program end, in last program block

39. M03 direction of spindle rotation clock wise direction
M04 direction of spindle rotation clock direction
M05 spindle stop, non-oriented
M19 oriented spindle stop, angle in degrees under addres-S
M36 Feed rate as programmed under -F
M37 Feed rate in mm/mm or mm/rev (Also active with G33)
M38 cancel M39
M39 Tapping mode
M40 Auto datum axis
M43 Raise tool detector
M44 Lower tool detector
M55 Zero offset group I
M46 Zero offset group 2
M47 Zero offset group 3
M54 Auto power down
L951 Pallet shuttle
CHAPTER 7

40. UNIVERSAL MILLING HEAD:
7.11 INTRODUCTION TO UNIVERSAL MILLING HEAD (UMH):
The universal milling head (Figure 9-7) mounts to the face of the Versa-Mil and is
driven by the spindle of the basic unit. This feature eliminates the need for special belts
and permits the head to operate at any angle. The milling head and the basic unit have the
same spindle taper and use the same arbors. With the universal head, machining can be
performed I along the side of the work, allowing the machining of much larger parts.
Angular operations such as thread milling can easily be performed on large diameter
material using the universal head.
The HUR 50 hand universal milling head is intended as an option to ft the following
horizontal milling machines: WH 10 CNC, WH(Q) 105 CNC, WHN(Q) 13 CNC, WHN
110/130 (Q, MC),WRD 130/ 150(Q), PRIMA,
OPTIMA, VARIA, VIVA, GRATA, MAXIMA I / II, MAGNA I / II.
Fig (7.1.a): Universal Milling Head
• The head serves to machine surfaces oriented in basic directions and in general relative
to the orthogonal coordinated system of the machine.
• The angles of turning in both parting planes of the head are set by means of a socket
handle after unfixing the individual rotary adjustable parts of the head.
• The adjustable parts of the head are mutually strengthened by tightening of bolts along
the circumference of the parting planes.
• The head can be set in 8 basic positions, using an arresting element (4 x90° in vertical
plane and 2x 1800
in angular plane).
• The angles of setting can be read on peripheral scales equipped with vernier of 0.10
increment.

41. • To obtain a more precise setting of position of the head spindle, it is necessary to use
Attachment of the head upon the machine headstock is carried out manually, by means
of a lifting device.
• The positioning and fixing of its adjustable base parts is carried out manually, by means
of screw.
7.21 WHY MILLING HEAD ATTACHMENT?
Naturally the scope of vertical milling of a horizontal machine with I vertical head
is more restricted than if a good vertical machine is available, I but not all shops have
sufficient vertical work to warrant the expense of a machine and for their purpose the head
is sufficient. As compared with the vertical machine, the head is less rigid and its spindle
much less generous in its dimensions. The head has no independent vertical movement for
its spindle as the vertical machine, and cut has to be put on by raising the knee. It has one
useful feature, however, which is not shared by many vertical machines, this is, and that it
may be swung round so that the spindle axis is inclined at angles other than the vertical,
and for some jobs this is a valuable feature.
The main advantage of CNC systems lies in the fact that the skills of the operator
required in the operations of a conventional machine is removed and the part production
is made automatic.
Milling head is a component which is used as an extra attachment on horizontal
boring machine. This component increases the versatility of the machining center by many
folds. Unlike the normal machining centre which machines only the plane of the
component normal to the spindle axis, the milling head is essentially useful for machining
the different planes of a component in one go without changing the setup of the machine
or the orientation of the e component.
The construction is such that the spindle rotation is imparted through two spindle
bevel gears and then to the milling head. This kind of movement of the spindle can be had
only when the rear side of the milling head has very high finish and the bore which houses
the milling head spindle also needs a very high finish (160 h7)
7.3) THE KEY SEQUENCE OF OPERATIONS:

42. Procedure like powering up, powering down, loading tools, setting offsets and
editing programs are among the things an operator will be doing on regular basis and
should strive to memorize. However there are also procedures that are used less often that
should also be documented.
Here is specific list of procedures for a typical CNC programming center. Very
similar procedures would b required for any of CNC machine tool.
THE MANUAL OPERATIONS:
• To start machine.
• To do a manual homing operation setup.
• To manually start spindle.
• To manually jog axes.
• To use the hand wheel to cause axis mbtion.
• To manually check out the dimensions.
7.51 PROCESS CARRIED OUT ON CNC MACHINE:
In our project, work piece is casted in initially. After casting the fettling is done.
The purpose of fettling is to chip off the fins, extra projections and to clean up the uneven
surfaces. After C milling centre provided in the jig boring section. Since the weight of the
component is around 30 kg and hence it is lifter by using crane priming, marking is done.
The required operations are carried out in the conventional machine tool, but not for the
required accuracy. To achieve the required accuracy, the component is sent to CN and
placed it on the bed. The CNC operator set the initial settlings. Component is placed it on
the bed. The CNC operator set the initial settlings. Component is placed in such a way that
rarer surface is on the bed.
The holes of dia 16mm are drilled on the component by using the tap of M18 * 2.5
+ 0.2 internal threading operation is done (Refer top view). The hole of a dia 10mm and
two holes of dia 7.8 mm are drilled on the component and reaming operation is done
subsequently. The holes of dia 7.8 mm are used for the purpose of oiling. Two holes of dia
10mm are drilled on the base plate to a depth of 7mm to a dia20mm. The purpose of these
two holes is to fix the component on the machine.

43. To perform the subsequent operations the bed is rotated 180 deg . Mill the bottom
faces to dia 270, dia 240, dia 2l5 and dia l60mm (Refer bottom view).
By using the crane the milling head is placed on the bed such that, bottom face is
on bed. The component is fixed to a correct position by using jig’s and fixtures. Mill the
front face to a dial40mm and dial10mm. Five holes of dia 10mm are drilled on this face.
It is an intermittent process because, if any urgent order of different item appears. Then
machining of that item is done. After completion of that item then again the operations are
carried out on the milling head. It is a batch production process, since the setup cost is
medium and labour content is also medium. Raw material inventory needed is moderate
and finished goods inventory varies since as the order comes from outside then only the
items are produced.
7.6) PROCESS LAYOUT

44. THE OPERATION LAYOUT OF UNIVERSAL MILLING HEAD:
OL-NO: HB51221 OLSLNO:10 Component: Milling head
OPERATION NO SECTION MACHINE
0A 1261 792
0B 1261 069
0C 1261 081
1 1264 090
2 1264 473
3A 1264 494
3B 1264 070
4 1265 083
5 1421 386
S.NO. SECTION MACHINE NO DESCRIPTION OF OPERATION
01 1261 792 SHOT BLASTING
0B 1261 069 FETTLING, chip off fins,
projections, etc., clean up uneven
surfaces
0C 1261 081 PRIMING (White painting)
1 1264 090 MARKING, mark off to distributor
machine allowance w.r.t. to bases
and bores
2 1264 473 H. Boring, Rough and finish
A) Mount on rear face and align,
bottom face:
Clean up bottom face ɸ140/ ɸ 110 by
reamer material for further opens.
B) Mount on bottom face level up
and align front face square to
spindle axis: Mill boss faces ɸ33 and
ɸ25 as per marking.
NB: Maintain same level within
0.01:

45. • Drill 4 holes ɸ 16* thro
• Tap M18 *25+2
dp.
• Drill and ream 1 hole ɸ
10-H7*thro
• Drill and ream 1 hole ɸ
7.8-H8*to open into bore for ɸ
7.8-H7
• C. Bore ɸ 11*3dp.
• Drill and tap 1 hole M16* to open
into
• Bore for ɸ spot face 2 holes ɸ 10
taper pin holes) ɸ28* to dim 117.
3A 1264 494 H.M. Center
N.B. Refer RH top view (fixture
J344029)
1) ON REAR SIDE
• Mill rear face (ɸ 270/ ɸ160) to 142,
inclined facing,
• Mill to form ɸ 270 15 Ig,
• Mill bore ɸ215*to dia 142,
• Mill bore ɸ160HB*15dp,
• Mill to form of at 45 degrees to R68,
• Drill 2 holes ɸ 10*thro
2) ON TOP SIDE
• Mill face ɸ 112 / ɸ 85 to dim 116.
• Bore ɸ85 – K6*35 lg.
• Drill and tap 3 holes N6*15 dp on
PCD 97.
3) ON BOTTOM SIDE
• Mill face ɸ 140 / ɸ 110 to dim 159.
• Bore ɸ 110-N6*84dp, incl.facing
• Drill and tap 5 holes HB *22dp.
3B 1264 070 FITTING:
Deburr completely.
Re-tap all taper holes.
4 1265 083 PAINTING:

46. Outside prime putty, rub down and
surface paint.
Inside: Brush 2 coats of red.
5 1421 386 DOWN DIVIDING:
Divide into 225 division of 10
each
ever sector of 225 degrees as per
drawing (Fixture J37400)

47. TOOLS:
T1 Dia 80 Shoulder mill-LG 187
T3 Dia 50 PORK PIN CUTTER-LG 220
T5 Dia 12 SPOT DRILL-LG 205
T7 Dia 95 BORING BAR-LG 250
T8 Dia 6.8 DRILL-LG 200
T10 Dia 10 DRILL-LG 225
T12 Dia 80 BORING BAR-LG 244K
T15 Dia 84.4 BORING BAR-LG 260
T17 Dia 20 END MILL FULL-LG 185
T18 Dia 5 DRILL-LG 185
T20 M6 TAP-LG 186
T22 M8 TAP-LG 192
T23 Dia 35 END MILL-LG 185
T25 END MILL (19.8)-LG 145
T28 Dia 105 B.BAR-LG 260
T30 Dia 109.4 B.BAR-LG 260
T31 Dummy tool change
T32 DIA 80/44 *90 SINGLE CUTTER DEG – LG-25
T34 DIA 85-K6 B.BAR LG 244
T37 DIA 110-M6 B.BAR LG 260
T39 DIA 80 S.H.MILL LG 187
PROGRAM

48. N50 TI DIA 80 SHOULDER MILL 182.7 LG
N55 L950
N60 G0 B90 G55
N70 G0 X500 Y375 Z500 D1, S300M3, T3
N80 Z397
N90 G1 X687.5 F200
N100 G2 X687.5 Y375.10 I0 J-105, F120
N110 G1 Y270
N120 G0 Z 372
N130 G1Y375 F200
N140 G2 X687.6 Y375 10 J-105 F200
N150 G1 Y270
N160 G0 Z388.8
N170 G1 Y375.5 F200
N140 G2 X687.6 Y375 10 J-105 F200
N150 G1 Y270
N160 G0 Z388.8
N170 G1 Y375.5 F200
N180 G2 X687.5 Y375 10 J-105 F200
N190 G1 Y270
N200 G0 G53 Z 675
N210 G0 B0 G54
N220 G0 XS987 Y100 Z400
N230 Z130
N240 G1 Y270 F200
N250 G2 X987 Y270 I-35 J0 F200

49. N260 G1 Y150
N270 G0 Z127
N280 G1 X952 Y235 F200
N290 G2 X952 Y235 I0 J35
N300 G0Z130
N310 Y395
N320 Z124
N330 G1 Y305 F200
N340 G2 X952 X305 I0 J-35 F200
N350 G1 X101.5
N360 Y155
N370 G0 G58 Z56
N380 Y155
N390 G0 X348 Y380 Z500
N400 Z205
N410 Z166
N420 G1Y287 F200
N430 G2 X348 Y287 I0 J-17 F200
N440 G1 Y380]
N450 G0 Z161]
N460 G1 X287 F200
N470 G2 X348 Y287 I0 J-17 F200
N480 G1 Y380
N490 G0 Z158
N500 G1 X287 F200
N510 G2X348 Y287 I0 J-17 F200

50. N520 G1 Y380
N530 G0 Z155.5
N540 G1 Y287 F200
N550 G2 X348 Y287 I0 J-17 F200
N560 G1 Y180
N570 X378
N580 Y360
N590 G0 G53 Z800
N600 G0 B90 G55
N610 G0 X787.5 Y270 Z500
N620 G1 G42 X687.5 F1000
N630 G0 Z384.5
N640 G2 X 687.5 Y335.10 J32.5 F200
N650 X687.5 Y335 I0 J65
N660 X720 Y302.5 I0 J-32.5 F1600
N670 G1 Y235 F500
N680 G2 X687.5 Y202.5 I-32.5 J0 F200
N690 X687.5 Y262 I0 J67.5
N700 X653.75 Y236.25 I0 J33.75 F500
N710 G0 Z425
N720 G1 Y320 F1000
N730 G40 X640.0
N740 G0X587.5 Y434
N750 G1 Z384.5 F500
N760 G41 Z384.5 F500
N770 G41X687.5 Y434 I0 J-164 F200

51. N780 G1 X848.5 F500
N790 Y20 F150
N800 G2 X848.5 F500
N810 G0 Z800
N820 G1 440 Y260 F1000
N830 G0 G53 Z800
N840 T3; (DIA 50 P.P. CUTTER 220 LG)
N845 L950
N850 G0 B90 G55
N860 G0 X587.5 Y433 Z500 D1 S430 M3;T12
N870 Z402.2
N880 G1 G41 X887.5 F100
N890 G2 X187.5 Y433 I0 J-163F1 10
N900 G1 X848 F1000
N910 Y310
N920 Y270 F100
N930 G2 X848 Y270 I-60.5 J0
N940 G0 Z500
N950 G1 G40 X600 F5000
N960 G0 X787.5 Y270 Z5000
N970 G1 G42 X687.5 F5000
N980 G0 Z401.8
N990 G2 X687.5 Y322 I0 J26 F100
N1000 X687.5 Y322 I0 J52
N1010 X713.5 Y296 I0 J-26 F500
N1020 G1 Y241.5

52. N1030 G2 X687.5 Y215 I-26 J0 F100
N1040 X687.5 Y215.10 J54.5
N1050 X660.25 Y242.75 I0 J27.5
N1060 G0 Z700
N1070 G1 G40 Y410 F5000
N1080 G0 G53 D0 Z800
N1090 T12;(DIA B.BAR 240 LG)
N1100 L950
N1110 G0 B180 G56
N1120 Z217.5
N1130 G1Z167.5 F115
N1140 G0 G53D0 Z800
N1150 T15; (DIA 811.4, B.BAR 260 LG)
N1160 G0 B180 G56
N1170 G0 X348 Y270 Z500 D1 S340 M3; T7
N1180 Z233.5
N1190 G1 Z183.5 F28
N1200 G0 G53 D0 Z800
N1280 T7 (DIA 95 B.BAR 250 LG)
N1285 L950
N1290 G0 B0 G54
N1300 G0 X 952 Y270 D1 S20 M3; T28
N1305 Z195
N1320 G1 Z85 F40
N1325 M5
N1210 T28; (DIA 105 B.BAR 260 260 LG)

53. N1215 L950
N1220 G0 B0 G54
N1230 G0 X 952 Y270 DI S200 M3; T28
N1240 Z201.4
N1250 G1 ZI13.3 F35
N1260 G04F2 M5
N1270 G0 G53 D0 Z800
N1340 T30; (DIA 109.4 B.BAR 260 LG)
N1345 L950
N1350 G0 B0 G54
N1370 Z201.5
N1380 G1 ZI 12.7 F21
N1390 G4 F2 M5
N1400 G0 G53 D0 Z800
N1410 T37; (DIA 80/44*90 SINGLE ANGLE CUTTER 235LG
N1415 L950
N1420 G0 B90 G55
N1430 G0 X650 Y270 Z500.01 S200 M4;T5
N1440 G1 G42 X687.5 F2000
N1450 G1 Z399.75 F2000
N1460 G2 X687.5 Y241I0 J-14.5 F100
N1470 X687.5 Y299 I0T29 F80
N1480 G0Z600
N1490 G1 G40 X700 F1000
N1500 G0 G53 D0 Z800
N1510 TS; (DIA 12 SPOT DRILL 205 LG)

54. N1515 L950
N1520 G0 B90 G55
N1530 G0 X687.5 Y364 Z500 D1 S500 M3; T8
N1540 Z407 F55
N1550 MCALL CYCLE 82(407,1105,5,398.5,2)
N1560 X687.5 Y364
N1570 Y176
N1580 MCALL
N1590 G0 G53 Z200
N1600 G0 B180 G56
N1610 G0 X327.75 Y312 Z400
N1620 Z178.5 F55
N1630 MCALL CYCLE82 (178.5, 173.5, 5, 170.5, 7)
N1640 X323.75, Y31
N1650 X396.5 Y270
N1660 X32.75 Y228
N1670 MCALL
N1680 G0 G53 Z600
N1690 G0 B0 G54
N1700 G0 X891 Y270 Z400
N1710 Z146.5 K55
N1720 M CALL (cycle82(146.5, 141.5, 138.2)
N1730 X891 Y270
N1740 X921.5 y322.827
N1750 X982.5
N1760 Y217.173

55. N1770 X921.5
N1780 MCALL
N1790 G0 G53 D0 Z800
N1800 T8; (DIA 6.8 DRILL 20 LG)
N1815 L950
N1810 G0 B0 G54
N1820 GP X891 Y270 Z400 D1 S795 M3; T10
N1830 Z141.5 F50
N1840 MCALL cycle82 (141.5, 136.5 5,106.52,2)
N1850 X891 Y270
N1860 X921.5 Y322.827
N1870 X982.5
N1880 Y217.173
N1890 X921.5
N1900 MCALL
N1910 G0 G53 D0 Z800
N1920 T10; (DIA 10 DRILL225 LG)
N1925 L950
N1930 G0 B90 G53
N1940 G0 X687.5 Y364 Z450 D1 S650 M3; T18
N1950 Z427 F80
N1960 MCALL cycle82 (427, 422, 5, 382, 2)
N1970 X687.5 Y364
N1980 Y176
N1990 MCALL
N2000 G0 G53 D0 Z800

56. N2010 T18 (DIA 5 DRILL 180 LG)
N2020 G0 B180 G56
N2030 G0 X323.75 Y312 Z400 D1 S650 M3
N2040 Z153 F50
N2050 MCALL cycle82 (153.5, 148.5,5,124.5,2)
N2060 X323.75 Y312
N2070 X396.5 Y270
N2080 X323.75 Y228
N2090 MCALL
N2100 G0 G53 D0 Z800
N2110 T20; (M6 TAP 186 LG)
N2115 L950
N2120 G0 B180 G56
N2130 G0 X323.75 X312 Z500 D1 S300 M3; Y T22
N2140 Z159.5 F300
N2150 MCALL cycle 840(159.5, 13.5, 135.5, 2,4,3,1)
N2160 X323.75 X312
N2170 X396.75 Y270
N2180 X323.75, 6228
N2190 MCALL
N2200 T22; (M8 TAP192 LG)
N2210 L950
N2220 G0 B0 G54
N2230 G0 X891 Y270 Z500 D1 S240 M3; T23
N2240 Z133.5 F100
N2250 MCALL cycle 840(133.5, 128.5, 5, 104.4, 1, 1,25, 3, 1,0)

57. N2260 X8917Y270
N2270 X921.5 Y322.87
N2280 X982.5
N2290 Y217.173
N2300 X921.5
N2310 MCALL
N2320 G0 G53 D0 Z800
N2330 T23; (DIA 35, END MILL 185 LG)
N2331 L950
N2340 G0 B90 G55
N2350 G0 X587.5 Y422.5 Z500 D1 S480 M3, T34
N2360 G1 G41 X650 F2000
N2370 G1 Z367 F2000
N2380 X687.5 F100
N2390 G2 X687.5 Y422.5 10 J-152.5 F100
N2400 G1 X698 F500
N2400 G1 X698 F500
N2410 G0 Z400
N2420 G1 G40 X 710 F500
N2425 M0
N2430 G0 G53 D0 Z800
N2440 T39 DIA 80 SHOLUDER MILL 187LG
N2441 L950
N2450 M0
N2460 G0 X1052 Y270 Z400 D1 S420 M3; T3
N2470 G1 G42 X952 F2000

58. N2480 G1 Z123.5 F2000
N2490 G2 X952 Y310 I0 J20 F300
N2500 X952 Y310 I0 J-40
N2510 G1 Z1020 F300
N2520 Y170
N2530 G0 Z800
N2540 G1 G40 Y160 F500
N2550 G0 G53 Z60
N2560 G0 B90 G55
N2570 X850 Y270 Z450
N2580 G1 G42 X687.5 F5000
N2590 G1 Z384.02 F2000
N2600 G2 X687.5 Y337.5 I0 J33.75 F300
N2610 X687.5 Y337.5 I0 J-67.5
N2620 X721.25 Y 303.75 I0 J-33.75 F500
N2630 G0 Z800
N2640 G1 G40 Y220 F2000
N2650 0 G53 D0 Z800
N2660 T31;(DUMMY TOOL CHANGE)
N2661 Z950
N2670 M0 (Manual loading Bar dia 160 h7 lg235.5
N2680 G0 B90 G55
N2690 G0 X687.5 Y270 Z600 D1;T25
N2700 Z438.5 S200 M3
N2710 G1 Z428 F20
N2715 M5

59. N2720 G0 Z800
N2730 M0;(CHECK BOR SIZE)
N2740 Z438.5 S200 M3
N2750 G1 Z417 F25
N2760 G4F2M5
N2770 G0 G53 D0 Z800
N2780 M0;(REMOVE DIA 60-B.BAR MANUALLY)
N2790 T25;(DIA 19.8 END MILL 145 LG)
N2791 L950
N2800 G0 B90 G55
N2810 G0 X687.5 Y400.1 Z400 D1 S430 M3;T34
N2820 Z342.02
N2830 G1 G41 X687.5 F100
N2840 G2 X687.5 Y400.1 IO J-130.1 F100
N2850 G1 X737.5 F100
N2860 G40 X750 F500
N2870 G0 Z700
N2880 MP; (CHECK UP WITH 0.4 ALLOWANCE)
N2890 G0 X607.5 Y399.9 M3
N2900 Z342.02 M3
N2910 G1 G41 X687.5F100
N2920 G2 X687.5 Y399.9 IO J-129.9 F100
N2930 G1 X737.5 F100
N2940 G0 Z600
N2950 G1 G40 6250 F2000
N2960 G0 G53 D0 Z800

60. N2970 X1290 M0; (DIA 240 TO BE SHOWN)
N2980 T34; (DIA 86K6 B.BAR 244 LG)
N2990 G0 B180 G56
N3000 G0 X348 6270 Z500 D1 S430 M3; T37
N3010 Z217.5
N3020 G1 Z207.5F18
N3025 M5
N3030 G0 Z800
N3040 M0; (CHECK BOR SIZE)
N3050 G0 Z217.5 M3 D1
N3060 G1 Z167.5 F18
N3065 M5
N3070 G0 G53 D0 Z800
N3080 T37; (DIA 110-M6 B.BAR 260 LG)
N3081 L950
N3090 G0 B0 G54
N3075 M0; (REMOVE B BAR CHECK INDEXING OFFSER AND B.BAR)
N3100 G0 X952 Y270 Z500 1 S250 M3; T17
N3110 Z201.5
N3120 G1 Z191 F18
N3130 G0 Z800
N3140 M0; (CHECK BORE SIZE)
N3150 G0 Z201.5 M3
N3160 G1 Z112.5 F18
N3170 G1 F2 M5
N3180 G0 G53 D0 Z800

61. N3190 T17; (DIA 20 ENDMILL 285 LG USE CORRECT SIZ END MILL)
N3191 L950
N3200 G0 B90 G55
N3205 G0 X51.497 Y362.75 X390 S450 M3 D1
N3220 G1 Z355 F100
N3230 G02 X561, 497 Y197.25 1126.003 J-72.75 F100
N3240 G1 G40 X541, 497 Y177, 25 F500
N3250 G0 G53 D0 Z800
N3255 T0
N3260 L950
N3270 M30
MACHINING TIME
1. CONVENTIONAL METHOD – HORIZONTAL MILLING CENTRE:
S.No. Machine Name TS in min. TO in min.
Total
Time
1. HORIZONTAL
MILLING
CENTRE
720 4122 48421
TOTAL TIME: 4842 / 60
2. NON-CONVENTIONAL METHOD – CNC PART PROGRAMMING:
S.No. Machine Name TS in min. TO in min.
Total
Time
1. HMC
KTM – 760
240
TOTAL TIME = 1614 / 60
= 27 HRS.