“MANUFACTURING OF ALLUMINIUM RELAY MECHANICAL BOX”

A
INDUSTRIAL ORIENTED MINI PROJECT REPORT
SUBMITTED IN THE PARTIAL FULFILLMENT
OF THE REQUIREMENT FOR THE AWARD OF
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
SUBMITTED BY
KUDUKUNTLA RAVISAGAR (16RA5A0307)
UNDER ESTEEMED GUIDANCE OF

MS. P HARIKA
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
KPRIT COLLEGE OF ENGINEERING GHATKESAR

DEPARTMENT OF MECHANICAL ENGINEERING

KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
GHANPUR, GHATKESAR, MEDCHAL MALKAJIGIRI(DIST), TELANGANA-
500088

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(Affiliated to JNTU, HYDERABAD & Accredited by NAAC)
Ghanpur, Ghatkesar ,Medchal 500088

CERTIFICATE

This is to certify that he mini project work entitled “ A STUDY ON

COMPUTER NUMERICAL CONTROL (CNC) MACHINE” is a bonafide
work carried out by ALAALA RANJITH (16RA1A0308) , in partial fulfillment
of the requirement for the degree of BACHELOR OF TECHNOLOGY in
MECHANICAL ENGINEERING by Kommuri prathap reddy insititution of
technology during the academic year 2016-2020
The results embedded in this report have not been submitted to any
other university or Board or Institution for the award of any degree or diploma.

Project Coorrdinate Head of the Department

Ms. P Harika Mr. p vinay kumar

Assistant Professor Assistant Professor
Department of mechanical engineering Department of mechanical engineering

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CERTIFICATE

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 PREFACE

 Training is an integral part of B.Tech and each and every student

has to undergo the training for 4-6 weeks in a company.

This record is concerned about our practical training during the summer vacations
after 3rd year. We have taken our practical training in “RAJESHWARA RINGS Pvt.
Ltd(RRPL)” .During this training, we got to learn many new things about the CNC
machine. This training provide to be a milestone in our knowledge of present industry.
Every say and every moment was an experience in itself, an experience which
theoretical study can’t provide.

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 ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people, who directly or indirectly

contributed in the development of this work and who influenced my thinking,
behavior and acts during the course ofstudy.
I expressmy sincere gratitude to Mr.P VINAY KUMAR ( Head Of Department)&
Faculty of Mechanical Department for providing me an opportunity to undergo
summer training at “RAJESHWARA RINGS Pvt.Ltd”(RRPL).

And I also express my sincere gratitude to “Mr.K SIVA RAMA

KRISHNA”(Production Manager) for providing me a platform like RRPL toincrease
my technical knowledge as well as gaining practical knowledge in CNC Machine,
which helps me to achieve a better job opportunity in my field.

Lastly, I would like to thank the almighty and my parents for their moral support and
my friends with whom I shared my day-to-day experience and received lots of
suggestions that my quality of work.

A.RANJITH
16RA1A0308
B.Tech (Mech)

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 ABSTRACT

The main objective of this paper is to “Study on Computer Numerical Control

(CNC) machines for fabrication of rollers. This paper also includes various processes
like facing, turning, parting, drilling, boring and knurling to improve production in
order to decrease the production time and also to increase the efficiency in
conventional lathe and CNC machines.

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CONTENTS

Sr No Name of the Chapter

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8
LIST OF FIGURES

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 CHAPTER 1

1.1 INTRODUCTION TO CNC

 The design is loaded into the computer which is attached to the CNC machine.
The computer changes the design into a special code (numerical) that controls
the way the CNC cuts and shapes the material.
 The material to be shaped is taped on to a block with double sided tape. This
must be done carefully so that it does not come off the block during
machining.
 The block is then placed in the vice, inside the CNC. It must be tightened up
carefully. If it is not secure when the machine starts to cut the material it can
come away from the vice. When the machine starts working, the vice moves
up, down, right and left according to the design.
 The guard is placed in position. It protects the machine operator in case the
material is pulled out of the vice by the power of the cutter. For safety reasons,
if the guard is not in position the motor will not start.
 The CNC is turned on and the shape is cut from the material. When the cutter
has stopped the shaped material can be removed from the vice. Total time - for
simple designs - 15 minutes.

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 Fig 1

1.1 .1 CNC Input Machine

Process, Output A CNC production facility needs three pieces of equipment. A
Computer The computer is used to draw the design. However, the design is only a
picture and the CNC machine cannot use this to manufacture the product. The
computer software must also convert the drawing into numbers (coordinates) that the
CNC machine can use when it starts to cut and shape the material.

1.1.2 An Interface
A computer cannot be directly connected to a CNC machine. The computer is
connected to an interface. This converts the signals from the computer to a form that
the CNC machine understands. The signals are in the form of digital signals when
they Machine are sent to the CNC machine.

1.1.3 CNC (Computer Numerical Control) The signals from the interface control
the motors on the CNC machine. The signals determine the way the vice moves. The
vice moves in three directions X, Y and Z. (Horizontally, vertically and depth). The
signals also control the speed of the cutting tool.

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1.2 CNC Control Panel

A CNC machine is normally controlled by a computer and software. However,

most CNC machines have a range of controls for manual use. It is rare for a CNC
machine to beused manually as simple operations are best carried out on
cheap/basic/manual machines. When a CNC machine is used manually it is been
used well below its capability and specification.

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13
Reset Button

The most important control button is usually the reset button. When the CNC machine
is turned on, the reset button is pressed by the machine operator. This ‘zeros’ the
cutter, moving the cutter to coordinates 0, 0, 0 on the X, Y and Z axis. In simple
terms, the reset button moves the cutter to the corner of the machine, above the work
table. If the reset button is not pressed, it is possible that the CNC machine will start
cutting the material in the wrong place or even miss cutting the material and
plungeinto the work table.

Fig 3

Manual Control:

The cutter can be controlled manually although this is rarely needed. The ‘X’ and ‘Y’
buttons control the movement of the cutter along the horizontal surfaces. The ‘Z’
buttons control depth and up / down movement.

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Stop Button:
Most control panels have stop buttons. When pressed these stop the machine very
quickly.

Fig

Speed and Feed: On some CNC machines it is possible to manually vary the speed
and feed of the cutter.

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Fig

CHAPTER 2

2.1.1 Setting up the cutting tool to the correct length

One of the few operations that the machine operator carries out is to change the
cutting tool. Each CNC machine has a range of cutting tools. Straight cutters chamfer
V-groove and radius cutters are some examples. If a detailed design is being
manufactured, it may be necessary to change the cutting tool at least once during the
manufacturing process. It is very important that all the cutters are set up to exactly to
the same length in the collets. If this is not done the material being machined will be
machined at incorrect depths. A special depth gauge is used to accurately set up the
cutting tools. (See diagram below). This ‘rule’ applies to all CNC machines although
different techniques may be used depending on the type of the CNC machine.

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 Fig

2.1.2 CNC Machines and Safety

CNC machines are very safe to use as they are designed to be as safe as possible. One
of the main advantages of CNC machines is that they are much safer than manually
operated machines. The animation below shows a Boxford A3 HSRi2.CNC Router
with many of its safety features labeled.

1. Most modern CNC machines are designed so that the cutting tool will not start
unless the guard is in position .Also, the best CNC machines automatically lock the
guard in position whilst the cutter is shaping material. The guard can only be opened
if the cutter has stopped.

2. It is essential that pupils / students / machine operators receive ‘quality’ instruction

before attempting to use any CNC equipment.

3. CNC routers, used for shaping materials such as woods and plastics, have built in
extraction. Dust can be very dangerous if inhaled and can also cause eye irritation.
The CNC Router shown above has an outlet for an extraction unit. As the router is

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fully enclosed, dust cannot escape into the atmosphere. If an extraction unit is
attached the dust is removed automatically. Most manually operated machine
routers have very limited extraction systems which leave some dust in the air.

4. The CNC router above has a single phase electrical supply.Older machines such
as manually operated milling machines and centre lathes have three phase supplies. A
single phase electrical supply can be ‘plugged’ into any available socket. The
electrical supply for the machine comes through a residual circuit breaker (RCB). If
an electrical fault develops the RCB will cut off electrical power immediately.

5. Single phase CNC machines can be moved more easily because they are simply
unplugged and relocated. Three phase machines are specially wired by an electrician
into the electrical supply and cannot be unplugged.

6. Most CNC machines work behind a guard or even a closed, transparent safety door.
This means that the operated cannot be hurt by 'flying' pieces of sharp/hot material.

7. Commonsense applies to the use of all machines including CNC machines. Basic
safety training regarding working in a workshop and with other machines applies to
CNC machines as well.

CHAPTER 3

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 Fig

3.1.1 Programmable Functions

1 .The programmer must also know what functions of the CNC machine are
programmable (as well as the commands related to programmable functions). With
low cost CNC equipment, often times many machine functions must be manually
activated. With some CNC milling machines, for example, about the only
programmable function is axis motion. Just about everything else may have to be
activated by the operator. With this type of machine, the spindle speed and direction,
coolant and tool changes may have to be activated manually by the operator.

2.With full blown CNC equipment, on the other hand, almost everything is
programmable and the operator may only be required to load and remove work pieces.
Once the cycle is activated, the operator may be freed to do other company functions.

3. Reference the machine tool builder's manual to find out what functions of your
machine are programmable. To give you some examples of how many programmable
functions are handled, here is a list a few of the most common programmable
functions along with their related programming words.

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 3.1.2. Spindle control

An "S" word is used to specify the spindle speed (in RPM for machining centers). An
M03 is used to turn the spindle on in a clockwise (forward) manner. M04 turns the
spindle on in a counter clockwise manner. M05 turns the spindle off. Note that turning
centers also have a feature called constant surface speed which allows spindle speed
to also be specified in surface feet per minute (or meters per minute).

3.1.3 Automatic tool changer (machining center)

A "T" word is used to tell the machine which tool station is to be placed in the
spindle. On most machines, an M06 tells the machine to actually make the tool
change. Tool change (on turning centers) A four digit "T" word is used to command
tool changes on most turning centers. The first two digits of the T word specify the
turret station number and the second two digits specify the offset number to be used
with the tool. T0101, for example specifies tool station number one with offset
number one.

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3.2. Coolant control

M08 is used to turn on flood coolant. If available M07 is used to turn on mist coolant.
M09 turns off the coolant.

3.2.1. Automatic pallet changer

An M60 command is commonly used to make pallet changes.

3.2.3 Forms of compensation

different machine types, all forms of compensation allow the All types of CNC
machine tools require some form/s of CNC user to compensation. Though applied for
different reasons on allow for unpredictable conditions related to tooling as the
program is developed. Before discussing how compensation applies to CNC usage,
let's look at compensation in general terms.

Compensation is used in many facets of everyday life. The airplane pilot must
compensate for wind velocity and direction as a heading is set. The race car driver
must compensate for weather and track conditions as a turn is negotiated. A bowler
must compensate for the spin of the bowling ball as the ball rolls down the alley. A
marksman firing a rifle must compensate for the distance to the target. The marksman
analogy is amazingly similar to what happens with many forms of compensation on
CNC equipment.

3.2.4 Offsets

All forms of compensation work with offsets. You can think of CNC offsets as like
memories on an electronic calculator. If your calculator has memories, you know you
can store a constant value into each memory for use during a calculation. This keeps
you from having to enter the number over and over again with redundant calculations.

Like the memories of an electronic calculator, offsets in the CNC control are storage
locations into which numerical values can be placed. Just as the value within the
memory of a calculator has no meaning until referenced by its user within a

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calculation, neither does the value within an offset of the CNC control have any
meaning until it is referenced by a CNC program.

From the marksman analogy, you can think of the values stored in CNC offsets as like
the amount of adjustment required on the sight of the rifle necessary to compensate
for the distance to the target. Keep in mind that the rifle only needed adjustment for
one purpose, to adjust for the distance to the target. With most CNC machine tools,
there is a need for at least one offset per tool.

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 CHAPTER 4

4.1 PARTS OF CNC MACHINE

Fig Block Diagram of CNC Machine

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 Fig

(i) Input Devices: These are the devices which are used to input the part
program in the CNC machine. There are three commonly used input
devices and these are punch tape reader, magnetic tape reader and
computer via RS-232-C communication.

(ii) Machine Control Unit (MCU): It is the heart of the CNC machine. It
performs all the controlling action of the CNC machine, the various
functions performed by the MCU are

 It reads the coded instructions fed into it.

 It decodes the coded instruction

 .
 It implements interpolation ( linear, circular and helical ) to generate axis
motion commands.

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  It feeds the axis motion commands to the amplifier circuits for driving the axis
mechanisms
 .
 It receives the feedback signals of position and speed for each drive axis.

 It implements the auxiliary control functions such as coolant or spindle on/off

and tool change.

(iii) Machine Tool: A CNC machine tool always has a slide table and a spindle to
control of the position and speed. The machine table is controlled in X and Y axis
direction and the spindle is controlled in the Z axis direction

(iv) Driving System: The driving system of a CNC machine consists of amplifier
circuits, drive motors and ball lead screw. The MCU feeds the signals (i.e. of position
and speed) of each axis to the amplifier circuits. The control signals are than
augmented (increased) to actuate the drive motors. And the actuated drive motors
rotate the ball lead screw to position the machine table.

(v) Feedback System: This system consists of transducers that acts like
sensors. It is also called as measuring system. It contains position and speed
transducers that continuously monitor the position and speed of the cutting tool
located at any instant. The MCU receives the signals from these transducers and it
uses the difference between the reference signals and feedback signals to generate the
control signals for correcting the position and speed errors.

(vi) Display Unit: A monitor is used to display the programs, commands and other
useful data of CNC machine.

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 ADVANTAGES OF CNC MACHINES

 CNC (Computer Numerical Control machines) are widely used in

manufacturing industry. Traditional machines such as vertical millers, centre
lathes, shaping machines, routers etc. operated by a trained engineer have, in
many cases, been replaced by computer control machines.

 Machining is accurate
 Time taken to perform a job is very less
 Safe to operate
 Number of operators required to operate a machine are reduced
 No possibility of human error
 Reliable
 Even very complex designs can also be made
 Low maintenance required
 They are versatile
 Uniformity in designs
 They could run for all 24 hours a day

 DISADVANTAGES OF CNC MACHINES

 They are costly

 Trained operator is required to operate the machine
 In case of break down a highly skilled professional is required to solve
the problem

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 CHAPTER 5
CNC COORDINATE SYSTEM
FOR MILLING:
Nearly all CNC machine uses a Cartesian coordinate system based on an X, Y, and
Z axis. This system allows a machine to move in a specific direction along a specific
plane. Reduce the Cartesian system to its basics and you have a familiar number line.
One point on the line gets designated as the Origin.

Fig

Turning : it is a machining process in which a cutting tool, typically a non-rotary tool

bit, describes a helix tool path by moving more or less linearly while the work piece
rotates.

Fig

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11. POSITIONING OF MACHINE ORIGIN

Fixed zero: The programmer must determine the position of the tool relative to the
origin (zero point) of the coordinate system. Cnc either of two methods for specifying
the zero point. The first possibility is for the machine to have a fixed zero. In this
case, the origin is always located at the some position the machine table. Usually, that
position is the southwest corner(lower left-hand cornr) of the table and all tool
locations will be defined by positive X and Y coordinates.

Floating zero: : The second and more common feature on modern cnc machines
allows the machine operator to set the zero point any position on the machine table.
This feature is called floating zero. The part program is the one who decides where
the zero point should be located. The decision is based on part programming convince

Mode of positioning:

Absolute positioning: Another option sometimes available to the part programmer is

to use either an absolute system of tool positioning or an incremental system.
Absolute positioning means that the tool locations are always defined in relation to
the zero point. If a hole is to be drilled at a spot that is 8 in. Above the X axis 6 in. To
the right of the Y axis, the coordinate location of the hole would be specified as
X=+6.000 and Y=+8.000.

Fig

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Incremental positioning: Incremental positioning means that the next tool location
must be defined with difference to the previous too location. If in our drilling
example, suppose that the previous hole had been drilled at an absolute position of
X=+4.000 and Y=+5.000. Accordingly , the incremental position instructions would
be specified as X=+2.000 and Y=+3.000, in order to move the drill to the desired spot.

Fig

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 CHAPTER 6

6.1 Bearings
6.1.1 Rolling Bearings: A rolling element rotary bearing uses a shaft in a much larger
hole, and cylinders called "rollers" tightly fill the space between the shaft and hole. As
the shaft turns, each roller acts as the logs in the above example. However, since the
bearing is round, the rollers never fall out from under the load.

6.1.2 Rolling bearing construction: Most rolling bearings consist of rings with
raceway (inner ring and outer ring), rolling elements (either balls or rollers)
and cage. The cage separates the rolling elements at regular intervals, holds
them in place within the inner and outer raceways, and allows them to rotate
freely.

Raceway (inner ring and outer ring) or raceway washer 1) The surface on which
rolling elements roll is called the "raceway surface". The load placed on the bearing is
supported by this contact surface. Generally the inner ring fits on the axle or shaft and
the outer ring on the housing.

Fig

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TYPES OF BEARINGS :

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Rolling bearings divide into two main classifications: ball bearings and roller
bearings. Ball bearings are classified according to their bearing ring configurations:
deep groove type and angular contact type. Roller bearings on the other hand are
classified according to the shape of the rollers: cylindrical, needle, tapered and
spherical.

Rolling bearings can be further classified according to the direction in which the load
is applied; radial bearings carry radial loads and thrust bearings carry axial loads.

Other classification methods include: 1) number of rolling rows (single, double, or 4-

row), 2) separable and non-separable, in which either the inner ring or the outer ring
can be detached.

There are also bearings designed for special applications, such as: railway car journal
roller bearings, ball screw support bearings, turntable bearings, as well as linear
motion bearings (linear ball bearings, linear roller bearings and linear flat roller
bearings).Types of rolling bearings

Characteristics of rolling bearings: Rolling bearings come in many shapes and

varieties, each with its own distinctive features.

(1) The starting friction coefficient is lower and there is little difference between this
and the dynamic friction coefficient.
(2) They are internationally standardized, interchangeable and readily obtainable.
(3) They are easy to lubricate and consume less lubricant.
(4) As a general rule, one bearing can carry both radial and axial loads at the same
time.
(5) May be used in either high or low temperature applications.
(6) Bearing rigidity can be improved by preloading.

Construction, classes, and special features of rolling bearings are fully described in
the boundary dimensions and bearing numbering system section.

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Deep groove ball bearings

Fig
The most common type of bearing, deep groove ball bearings are widely used in a
variety of fields. Deep groove ball bearings include shield bearings and sealed
bearings with grease make them easier to use.

Deep groove ball bearings also include bearings with a locating snap-ring to facilitate
positioning when mounting the outer ring, expansion compensating bearings which
absorb dimension variation of the bearing fitting surface due to housing temperature,
and TAB bearings that are able to withstand contamination in the lubricating oil.

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Angular contact ball bearings: The line that unites point of contact of the inner ring,
ball and outer ring runs at a certain angle (contact angle) in the radial direction.
Bearings are generally designed with three contact angles.

Angular contact ball bearings can support an axial load, but cannot be used by single
bearing because of the contact angle. They must instead be used in pairs or in
combinations.
Angular contact ball bearings include double row angular contact ball bearings for
which the inner and outer rings are combined as a single unit. The contact angle of
double row angular contact ball bearings is 25˚.
There are also four-point contact bearings that can support an axial load in both
directions by themselves. These bearings however require caution because problems
such as excessive temperature rise and wearing could occur depending on the load
conditions.

Fig

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Cylindrical roller bearings: Uses rollers for rolling elements, and therefore has a
high load capacity. The rollers are guided by the ribs of the inner or outer ring. The
inner and outer rings can be separated to facilitate assembly, and both can be fit with
shaft or housing tightly. If there is no ribs, either the inner or the outer ring can move
freely in the axial direction.

Cylindrical roller bearings are therefore ideal to be used as so-called "free side
bearings" that absorb shaft expansion. In the case where there is a ribs, the bearing
can bear a slight axial load between the end of the rollers and the ribs. Cylindrical
roller bearings include the HT type which modifies the shape of roller end face and
ribs for increasing axial road capacity. And the E type with a special internal design
for enhancing radial load capacity. The E type is standardized for small-diameter
sizes.

Fig

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Tapered roller bearings
Tapered roller bearings are designed so the inner/outer ring raceway and apex of the
tapered rollers intersect at one point on the bearing centerline. By receiving combined
load from inner and outer ring, the rollers are pushed against the inner ring rib and roll
guided with rib.

Induced force is produced in the axial direction when a radial load is applied, so must
be handled by using a pair of bearings. The inner ring with rollers and outer ring come
apart, thus facilitating mounting with clearance or preload. Assembled clearance is
however hard to manage and requires special attention. Tapered roller bearings are
capable of supporting large loads in both the axial and radial directions

Fig

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Spherical roller bearings: Equipped with an outer ring with a spherical raceway
surface and an inner ring which holds two rows of barrelshaped rolling elements,
NTN spherical roller bearings are able to adjust center alignment to handle inclination
of the axle or shaft.

There are variety of bearing types that differ according to internal design.

Spherical roller bearings include as type equipped with an inner ring with a tapered
bore. The bearing can easily be mounted on a shaft by means of an adapter or
withdrawal sleeve.

The bearing is capable of supporting heavy loads, and is therefore often used in
industrial machinery. When heavy axial load is applied to the bearing, the load on
rollers of another row is disappeared, and can cause problems. Attention must
therefore be paid to operating conditions.

Fig

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Needle roller bearings:
Bearing unit Needle roller bearings use needle rollers as rolling elements. The needle
rollers are a maximum of 5 mm in diameter and are 3 to 10 times as long as they are
in diameter.

Because the bearings use needle rollers as rolling elements, the cross-section is thin,
but they have a high load capacity for their size. Because of the large number of
rolling elements, the bearings have high rigidity and are ideally suited to wobbling or
pivoting motion.

There is a profusion of types of needle roller bearings, and just a few of the most
representative types are covered here. For details, see the catalog devoted to the
concerned type of bearing.

Fig

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Thrust bearings : There are many types of thrust bearings that differ according to
shape of rolling element and application. Allowable rotational speed is generally low
and special attention must be paid to lubrication.

In addition to the ones given below, there are various types of thrust bearings for
special applications. For details, see the catalog devoted to the concerned type of
bearing.

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Fig

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CHAPTER
CONCLUSION:
In the study of computer numerical control machines the production improvement can
be done more effectively and efficiently.

The CNC programming is a way to operate CNC machine. CNC Lathe machine usage
gives many benefits of increased productivity and accuracy and time management but
the only drawback is its cost. This could not be employed for all small jobs and is
preferable to use in large amount of production and complicated shapes.

CNC Lathe machines are economical only for industrial purposes in large scale
production and is not suitable for small scale industries because of its high initial cost.

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