CENTRE OF EXELLENCE

1. CENTRE OF EXELLENCE SECTOR : PRODUTION AND MANUFATURAING (FIRST YEAR) BASIC-MODULE PMBT-06 BASIC CNC PROGRAMING & OPERATION AND HYDROLICS & PNEUMATICS (DURATION- 8 WEEKS)

2. HISTORICAL DEVELOPMENT OF AUTOMATION The early 19th century saw the invention of the steam engine, the internal combustion engine and the electric motor . These machines were initially all manually control is partly automatic. In other words , the control of the machines has been taken out of human hands . In the control of modern machines, numbers are used . Such control is called numerical control , often abbreviated to NC. Numerical control involves expressing as numbers all the data relating to the control of the machine. These numbers are referred to as numeric values . To tell the machine to carry out a different operation, all you have to do is enter a different series of numbers into the control box, so , logically enough , these series of numbers are called operating programs . Operating operating programs were later ‘written’ on punched tape or diskettes (floppy disks)

3. CNC INTRODUCTION This is slant version CNC lathe with versatile features for high productivity , quality, flexibility and reliability. This machine has been optimally designed for increased production rates, reduced setup times , compactness and minimum downtime. To accomplish this however, it is essential that the machine be well cared. This is suitable for both rough and finish machining of components from forgings and rolled bars to high accuracies. It is suitable for chuck work ,shaft work as well as bar work . It is capable of turning, facing, drilling, boring, threading, and grooving.

4. A programmable 8 station bi-directional turret is provided as a standard feature. This increases the efficiency of the machining by presenting the required tool within a few seconds. This manual will assist you in installing a system of servicing the machine and spotting maintenance problems. Your new turning machines has been thoroughly inspected and adjusted before it was delivered. Any adjustments to the operating mechanism and control should be made by qualified factory trained personnel . Do not attempt to repair or dissemble your machine unless you are trained to understand the mechanical, electrical and electronics system used in it .

5. NUMERICAL CONTROL: (NC) • NC involved entering a number of details into the machine in the form of numbers. The machine was thus programmed to perform in a certain way, which might for example involve a slide moving and the milling of a key way. Programming for an NC machine was done separately, away from the machine. The machine reads the program from a punched tape or cassette. One of the disadvantages of this system was that the program could not be altered. Once in the machine all the program information , including tool dimensions and the task of be performed, remained fixed.

7. COMPUTERIZED NUMERICAL CONTROL (CNC) CNC: Automatic operation become much move flexible when easily programmed computers were linked to NC machines. This so-called ‘Computerized numerical control (CNC for short) still involves NC: it is only the addition of the computer which is new, making flexible programming possible. A CNC system can be used with many different types of machines. This is possible because the CNC can use different system programs. Each different system program enables the CNC to control their different type of machine.

13. 14 SAFETY OPERATIONAL INSTRUCTIONS GENERAL SAFETY • Protect your eyes by wearing safety glasses. • Wear shoes with oil resistant soles. • If you have long hair, tie is back. • Do not wear long sleeves, loose clothing or neck ties. • Make sure that your area is free from chips, oil and coolant spills, air hoses or anything that may get in your way and make you to fall or slip. • Make sure that all cutting tools and work holding equipment are tight before running the spindle or moving the slides. • All maintenance and repair work should be done with the power off. If any work requires power ON, extreme care should be taken. • Keep the machine always clean and keep away the tools and gauges from getting damaged.

14. 15 B. MECHANICAL SAFETY • Care should be taken when removing a part for replacement or repair. Make sure that any connected or supported part can be safety left in the machine. If not, they should be removed also. Where orientation of adjacent parts may be important, matchmark parts before removing them. • When performing power ON maintenance or checking of moving parts, extreme caution should be taken. These parts can cause serious injury. • The machine should be lubricated according to the machine lubrication information given in this manual. • When performing maintenance of the hydraulic systems, the power must be OFF and there should be no pressure in the lines. • If you have removed any cover/guard for some reason, don’t forget to refit them before you start the machine.

15. 16 C. SAFETY CHECK ON THE MACHINE – BEFORE START • Check the voltage and current. • Check the lubricant tank oil level. • Check the hydraulic tank oil level. • Check the clamping devices. • Check and clean the machine. • Check the clamping stock.

16. 17 D. SAFETY CHECK ON THE MACHINE • Check the main pressure of the hydraulic/pneumatic system • Check the clamping pressure of the hydraulic/pneumatic system for chuck/fixture. • Check the chuck function. • Lubricate the clamping device if any manual. • Move the slides to Ref. point in Ref. point return mode. • Jog the slides to and fro and check the sliding movement. • Check the Centralized lubricant System manual of pressing app. Switches. • Check the coolant supply by pressing app. Switches. • Check the selectable zero offset entries.

17. 18 MAINTENANCE A. PREVENTIVE MAINTENANCE • Many of the service problems that occur over the lift of any Machine • tool can be avoided through the application of proper Preventive • maintenance practices. The purpose of this section Of the manual is to • help you in setting up a regular schedule of Periodic preventive • maintenance measures for your CNC lathe. • Keeping the machine clean is an important part of preventive • Maintenance. Cleaning the machine takes only a few minutes Each • shift when done on a regular basis. A program of this type Helps • in keeping the point from becoming stained and the bright Metal • parts from becoming rusted or discolored. Wipe the Machine • thoroughly with a rig soaked in kerosene., if the machine Is in an • atmosphere where bright metal parts rust quickly , wipe them with • a rag soaked in clear mineral oil .never use Caustic cleaner or • cleaning compounds on the machine because the abrasion can Ruin • the finish . Do not use air for cleaning purpose. The pressure will drive • dirt and Chips into bearing surfaces.

18. B PREVENTIVE MAINTENANCE CHECK LIST 19 The following maintenance intervals are suggested for use under Optimum conditions. If environmental conditions warrant, the Frequency of maintenance intervals should be increased. • Every eight hours of machine operation: • Check cleanliness of slideways. • Check slideway lubrication. • Check hydraulic oil reservoir level. Every forty hours of machine operation: 1) Wash the machine throughly and wipe down. • Every one hundred and sixty hours of machine operation: • Clean oil filters. • Check for dirt, oil and water inside the machine electronic cabinet. • Check for an air tight seal of the machine electronic cabinet. • Check tightness of screws on terminal boards and relays • Every thousand hours of machine operation: • Check all motor drive belts for deterioration, wear and tension. • Clean and wash all way wipers and check for wear condition. • Drain and flush main hydraulic oil reservoir and refill with fresh hydraulic oil.

19. 20 C. NORMAL OVERHAUL CHECK LIST FOR HYDROLIC SYSTEM • Send sample oil drawn from tank for laboratory or makers test. • Drain off oil, store top 90 percent in clean, dry drums. Drain off remaining • ten percent and scrap. • Clean out sludge in tank, check for rust and condition of paint. Scrape and • paint if required with correct paint. • Change element of air breather on tank or clean element in solvent and • replenish with correct oil, according to type. • Clean strainer in tank filling plug. • Replace elements in main filters. • 7) Examine flexible hoses for signs of deterioration of lining, proper attachment • of end fittings and possible cracking here and at points of maximum flexing. • 8) Check free running of pump and motor. • 9) Check for end play and side play in pump and motor shafts, indicating • bearing wear. • 10) Check free movement of valve spool etc. • Check for operations of solenoids and relays. • 11) Top up oil to correct level. • 12) Tighten oil pipe connections. Do not over strain.

20. 21 MACHINING CENTRES These are very important types of CNC Machine Tools and are multifunction Machines equipped with automatic tool changers and are capable of carrying out milling, drilling, teaming, tapping, boring, counter boring and allied operations-without operator intervention for change of tools ACCORDING TO THE SPINDLE CONFIGURATION • Horizontal spindle machining centers • Vertical spindle machining centers • Universal machining centers

23. TURNING CENTRES / CNC LATHES 24 These are other types of popular CNC machines and are generally classified as: • Horizontal machines and • Vertical machines Classification of the Horizontal Machines (A) CHUCKING MACHINES (B) SHAFT LATHES (C) UNIVERSAL LATHES (D) TOOLING AND TURRET SLIDE

26. CNC CUTTING TOOL MATERIALS 27 (1)UNCOATED HARD METALS (ISO GROUP HW) (2) COATED HARD METALS ( ISO GROUP HC ) (3) CEMENTS ( ISO GROUP HT ) (4) CEREMIC CUTTING MATERIALS ( ISO GROUP C ) (5) POLYCRYSTALLINE CUTTING MATERIALS (6) CUBIC BORON NITRIDE ( ISO GROUP BN ) (7) POLYCRYSTALLINE DIAMOND ( ISO GROUP DP ) (8) CUTTING MATERIAL CHART

27. 28 Selection Of Cutting Parameters & Tools • Selection Of Tools, Speed, feed & Depth Of Cut. D = Work piece diameter m.m. V = Cutting speed m/min. S = Feed mm/ r N = R.P.M. r/min A = Depth of Cut m.m. N = Efficiency for Ex. 0.75 Ks = Specific Cutting Force n/m.m.2 V = metal removal rate cm3/min P = power required KW R = nose radius mm. K = Constant for Exp.1.4 Rt = Profile depth µm Ra = Surface finish µm

28. 29 RPM

29. 30 PRODUCT The SINUMERRIK 810T is a microprocessor –controlled CNC continuous path control system for compact Machine tools. • The SINUMERIK 810T • is used primarily to control turning machines • Programming can be either computer –aided or manual • Operation: - Soft keys for selecting different soft keys functions - 9” graphics screen -Address/numerical keyboard and function keys • Screen displays provide information in plain text Covering : - current NC operating modes - Set point / actual values -NC and PLC alarms. ….. …….

30. 31 Graphics displays aid the programmer when entering Programs at the machine “Blueprint programming’’ is available for higher –speed Programming of complex contour elements Entered programs may be simulated graphically The SINUMERIK 810 T can process 9999 main programs and 9999 subroutines 200 main programs and subroutines can be stored Simultaneously in the memory Lengthy part programs can be excused using optional “BLOCK TRANSFER’’ function.

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