face milling operation on a CNC machine.

1. Title: To prepare a Pocket of Aluminum by face Milling on CNC Milling machine
Location: CIM Center
Machining Capacity
MANUFACTURING PROCESSESS LAB – VI
Student’s Name: MUHAMMAD SHEHRYAR IMTIAZ Registration Number/Roll No. ME181056
Max. Marks: 25
A. Introduction
THE MILLING OPERATION
CNC stands for computer numerically controlled. As a milling technique, this means that a design
can be specified on a computer using CAD tools, and that a computer can handle the milling
process. And the program is able to specify the movements that the mill and table mustmake.
CNC milling is a specific form of computer numerical controlled (CNC) machining consisting of
both the drilling and cutting. Mill uses a rotating cylindrical cutting tool. However, the cutter in a
milling machine is able to move along multiple axes, and can create a variety of shapes, slots and
holes. In addition, the work-piece is often moved across the milling tool in different directions,
unlike the single axis motion of a drill.
INTRODUCTION OF THE MACHINE
In the machine, the labelled axes, X and Y designate horizontal movement of the work-piece
(forward-and-back and side-to-side on a flat plane). And Z represents vertical, or up-and-down
movement.
CNC milling machine also integrate a device for pumping cutting fluid to the cutting tool during
machining. This machine can be used to produce a wide range of components, and tooling costs
involved have continued to become more affordable day by day. It provides ideal solutions to
everything ranging from prototyping and short-run production of complex parts to the fabrication
of unique precision components.
MACHINABLE MATERIALS
Virtually every type of material that can be drilled or cut can be machined by a CNC mill, although
most of the work performed is done in metal. As with drilling and cutting, the proper machine tools
must be selected for each material in order to avert potential problems. The hardness of the work-
piece material, as well as the rotation of the cutting tool must all be factored before beginning the
machining process
To manufacture a Pocket of Aluminum by face Milling on CNC machine

2. Title: To prepare a Pocket of Aluminum by face Milling on CNC Milling machine
Location: CIM Center
G codes and M codes for CNC machine controls
G-code is a common name for the programming language that is used for NC and CNC machine
tools. It is defined in EIA RS-274-D. G-code is also the name of any word in a CNC programthat
begins with the letter G, and generally is a code telling the machine tool what type of action to
perform, such as:
✓ Rapid move
✓ Controlled feed moves in straight line or arc
✓ Series of controlled feed moves that would result in a hole being drilled.
✓ Change a pallet
✓ Set tool information such as offset.
There are other codes; the type codes can be thought of like registers in a computer
✓ X position
✓ Y position
✓ Z position
✓ M code (another "action" register)
✓ F feed rate
✓ S spindle speed
✓ N line number
✓ R Radius
✓ T Tool selection
✓ I Arc data X axis
✓ J Arc data Yaxis
G-code files are output by CAM software such as Smartcam, Gibbscam, Featurecam, Edgecam,
Mastercam, etc. G-code is also output by specialized CAD systems used to design printed circuit
boards. Such software must be customized for each type of machine tool that it will be used to
program.
G & M-Code programming language used in the CNC Machining Industry.
CNC G Codes
G00 - Positioning at rapid speed; Mill and Lathe
G01 - Linear interpolation (machining a straight line); Mill and Lathe
G02 - Circular interpolation clockwise (machining arcs); Mill and Lathe

3. Title: To prepare a Pocket of Aluminum by face Milling on CNC Milling machine
Location: CIM Center
G03 - Circular interpolation, counter clockwise; Mill and Lathe
G04 - Mill and Lathe, Dwell
G09 - Mill and Lathe, Exact stop
G10 - Setting offsets in the program; Mill and Lathe
G12 - Circular pocket milling, clockwise; Mill
G13 - Circular pocket milling, counterclockwise; Mill
G17 - X-Y plane for arc machining; Mill and Lathe with live tooling
G18 - Z-X plane for arc machining; Mill and Lathe with live tooling
G19 - Z-Y plane for arc machining; Mill and Lathe with live tooling
G20 - Inch units; Mill and Lathe
G21 - Metric units; Mill and Lathe
G27 - Reference return check; Mill and Lathe
G28 - Automatic return through reference point; Mill and Lathe
G29 - Move to location through reference point; Mill and Lathe (slightly different for each
machine)
G31 - Skip function; Mill and Lathe
G32 - Thread cutting; Lathe
G33 - Thread cutting; Mill
G40 - Cancel diameter offset; Mill. Cancel tool nose offset; Lathe
G41 - Cutter compensation left; Mill. Tool nose radius compensation left; Lathe
G42 - Cutter compensation right; Mill. Tool nose radius compensation right; Lathe
G43 - Tool length compensation; Mill
G44 - Tool length compensation cancel; Mill (sometimes G49)
G50 - Set coordinate system and maximum RPM; Lathe
G52 - Local coordinate system setting; Mill and Lathe
G53 - Machine coordinate system setting; Mill and Lathe
G54~G59 - Workpiece coordinate system settings #1 t0 #6; Mill and Lathe
G61 - Exact stop check; Mill and Lathe
G65 - Custom macro call; Mill and Lathe
G70 - Finish cycle; Lathe
G71 - Rough turning cycle; Lathe
G72 - Rough facing cycle; Lathe
G73 - Irregular rough turning cycle; Lathe
G73 - Chip break drilling cycle; Mill
G74 - Left hand tapping; Mill
G74 - Face grooving or chip break drilling; Lathe
G75 - OD groove pecking; Lathe
G76 - Fine boring cycle; Mill
G76 - Threading cycle; Lathe
G80 - Cancel cycles; Mill and Lathe
G81 - Drill cycle; Mill and Lathe
G82 - Drill cycle with dwell; Mill
G83 - Peck drilling cycle; Mill
G84 - Tapping cycle; Mill and Lathe
G85 - Bore in, bore out; Mill and Lathe
G86 - Bore in, rapid out; Mill and Lathe

4. Title: To prepare a Pocket of Aluminum by face Milling on CNC Milling machine
Location: CIM Center
G87 - Back boring cycle; Mill
G90 - Absolute programming
G91 - Incremental programming
G92 - Reposition origin point; Mill
G92 - Thread cutting cycle; Lathe
G94 - Per minute feed; Mill
G95 - Per revolution feed; Mill
G96 - Constant surface speed control; Lathe
G97 - Constant surface speed cancel
G98 - Per minute feed; Lathe
G99 - Per revolution feed; Lathe
CNC M Codes
M00 - Program stop; Mill and Lathe
M01 - Optional program stop; Lathe and Mill
M02 - Program end; Lathe and Mill
M03 - Spindle on clockwise; Lathe and Mill
M04 - Spindle on counterclockwise; Lathe and Mill
M05 - Spindle off; Lathe and Mill
M06 - Toolchange; Mill
M08 - Coolant on; Lathe and Mill
M09 - Coolant off; Lathe and Mill
M10 - Chuck or rotary table clamp; Lathe and Mill
M11 - Chuck or rotary table clamp off; Lathe and Mill
M19 - Orient spindle; Lathe and Mill
M30 - Program end, return to start; Lathe and Mill
M97 - Local sub-routine call; Lathe and Mill
M98 - Sub-program call; Lathe and Mill
M99 - End of sub program; Lathe and Mill
B. Programming
Write the program for the manufacturing of a Pocket of Aluminum by face Milling on CNC
Milling machine and also attach the drawing also.

5. Title: To prepare a Pocket of Aluminum by face Milling on CNC Milling machine
Location: CIM Center
C. Result
A Pocket of Aluminum by face Milling on CNC machine is prepared.
C. Lab Discussion
Q1) How many types of Face milling operations are there. Describe them briefly? [5]
Face milling:
In face milling, the axis of the cutter is perpendicular to the surface being milled, and machining is
performed by cutting edges on both the end and outside periphery of the cutter.
Types of face milling:
1. Conventional face milling:
In which the diameter of the cutter is greater than the work part width, so the cutter overhangs the
work on both sides.
2. Partial face milling:
Where the cutter overhangs the work on only one side.
3. End milling:
In which the cutter diameter is less than the work width, so a slot is cut into the part.
4. Profile milling:
A form of end milling in which the outside periphery of a flat part is cut.
5. Pocket milling:
Another form of end milling used to mill shallow pockets into flat parts.
6. Surface contouring:
In which a ball-nose cutter (rather than square end cutter) is fed back and forth across the work
along a curvilinear path at close intervals to create a three-dimensional surface form.
Q2) What is the difference between face mill and end mill cutters? [4]
Face milling cutters have a cutting edge on the end face and outer circle perpendicular to the arbor,
which are mainly used for milling planes. The cutting edge of the outer circle is the main cutting
edge, and the cutting edge of the end face plays the same role as the scraper. Face milling cutters
have shorter blades than sleeve end mills.
End milling is one of the most used milling cutters on CNC machine tools. Both the cylindrical
surface and the end surface of the end mill have cutting cutters. They can be cut simultaneously or
separately. Mainly used for plane milling, groove milling, step face milling and profiling milling.

6. Title: To prepare a Pocket of Aluminum by face Milling on CNC Milling machine
Location: CIM Center
End milling can be used as face milling. However, because the main declination angle is 90°, the
force of the tool is mainly radial force in addition to the main cutting force, which is easy to cause
deflection and deformation of the arbor, and it is also easy to cause vibration, which affects the
processing efficiency. Therefore, except for similar to the thin-bottom workpiece Except for special
reasons such as small axial force or occasional face milling, which is occasionally necessary to
reduce the variety of tool stocks, it is not recommended to use an end mill to machine flat surfaces
without steps.
Face milling cutter blades VS. end milling cutter tool head
Q3) In which operation do you think are more forces acting on the tool, Milling or Drilling,
even if machining is done with similar cutting parameters and materials? Why? [3]
In drilling you need axial thrust bearing while milling needs radial bearing.
Milling machines use an incredible amount of force. You won’t experience any vibrations or shaking
like you would with low-quality drills.
The results are often much cleaner, leaving hardly any metal debris behind. You’ll also notice that it’s
much quicker since it doesn’t have to go over the same area multiple times.
Milling machines allow you to rotate and move the bit while it’s cutting. Unlike a drill press that has
to go vertically when it’s cutting, you can rotate the bit on a milling machine for unique angles and
cuts. That’s why the milling shaft need to be fed with huge torque to beat the reverse torque from the
tool while it makes a cut.
Drills are much quicker to use from start to finish. You don’t have to adjust as many settings since
it’s very straightforward. Turn it on, place it where it needs to go, set the speed, place the correct bit,
and get to drilling. Not much force is acting on the tool bit since its made from materials which can
bear high shear stress from the workpiece.

7. Title: To prepare a Pocket of Aluminum by face Milling on CNC Milling machine
Location: CIM Center
Q4) It is said that the tool material should have a good “hot hardness”. Why this property is
important for tool material? (Explain in reference to tool wear) [3]
Hot Hardness:
Generally, hardness is measured at room temperature. But the term Hot hardness indicates that the
hardness at elevated temperature. We know that the hardness decreases as temperature increases. In
metal cutting, heat is generated during the process. The tool material must be able to maintain its
hardness, wear resistance and strength at such a high elevated temperature, which ranges nearly
600°C to 1800°C.
Q5) A face milling operation is used to machine 6.0mm from the top surface of a rectangular
piece of Aluminium 300 mm long by 125 mm wide in a single pass. The cutter follows a path
that is centred over the work piece. It has four teeth and is 150 mm in diameter. Cutting speed
= 2.8 m/s, and chip load = 0.27 mm/tooth. Determine
(a) The actual machining time (Tm) to make the pass across the surface. [8]
(b) The maximum metal removal rate (MRR) during cutting. [2]
(ATTACHMENT)

8. Title: To prepare a Pocket of Aluminum by face Milling on CNC Milling machine
Location: CIM Center