LAB MANUAL

(METAL CUTTING LAB)

Officer Incharge:
Dr. M. S. Niranjan
 LIST OF EXPERIMENTS

1. To study different machines in lab.

2. To study Capstan Lathe.

3. To study the effect of cutting speed, feed and drill diameter on the
thrust and torque in radial drilling machine using a dynamometer.

4. To determine the tool life of a given H.S.S tool.

5. To study and find out the effect of change in cutting speed, feed
and depth of cut on cutting force and feed force while turning
using a lathe tool dynamometer.

6. To study the effect of cutting speed, feed, depth of cut and rake
angle on cutting ratio and shear angle.

7. To study CNC Turning Centre.

8. To perform operation in CNC Turning Centre.

9. To study CNC Vertical Milling Centre.

10. To perform operation in CNC Vertical Milling Centre.

 EXPERIMENT NO. 1

AIM: To study different types of machines in lab.

LATHE MACHINE

The main function of a lathe is to remove metal from a piece of work to give it
the required shape and size. This is accomplished by holding the work securely
and rigidly on the machine and then turning it against cutting tool which will
remove metal from the work in the form of chips. To cut the material properly
the tool should be harder then the material of the workpiece, should be rigidly
held on the machine and should be fed or progressed in a definite way relative to
the work.

Lathe Machine

UPRIGHT OR COLUMN DRILLING MACHINE

Upright or column drill is similar to the sensitive drill machine the only
difference is that the power feeding mechanism is used for the rotation of the
drill. This machine is mostly suited for heavy work. The size of work that can be
accommodated is limited by the distance between the spindle and column. These
machines mostly have a box type column and are mostly used for heavier work.

Upright or column drilling machine

RADIAL DRILLING MACHINE

The radial drilling machine is intended for drilling medium to large and heavy
work pieces. It consists of a heavy, round, vertical column mounted on a large
base. The column supports a radial arm which can be raised and lowered to
accommodate work pieces of different heights. The arm may be swung around
to any position over the work bed. The drill head containing mechanism for
rotating and feeding the drill is mounted on the radial arm and can be moved
horizontally on the guide ways and then clamped at any desired position. These
three movements in a radial drilling machine when combined together permit
the drill to be located at any desired point on a large workpiece for drilling the
hole. When several holes are drilled on a large workpiece, the position of the
arm and the drill head is altered so that the drill spindle may be moved from one
position to another.
 Radial Drilling Machine

MILLING MACHINE

Milling is the process of machining flat, curved, or irregular surfaces by feeding

the workpiece against a rotating cutter containing a number of cutting edges.
The milling machine consists basically of a motor driven spindle, which mounts
and revolves the milling cutter, and a reciprocating adjustable worktable, which
mounts and feeds the workpiece.

Milling machines are basically classified as vertical or horizontal. These

machines are also classified as knee-type, ram-type, manufacturing or bed type,
and planer type. Most milling machines have self-contained electric drive
motors, coolant systems, variable spindle speeds, and power operated table
feeds.

Vertical Milling Machine

In this machine, the spindle axis is aligned in a vertical direction. The base of
vertical milling machines is made up of cast iron as it has higher compressive
strength. The screw jack is attached to the base and it moves in the vertical
direction. Also, this machine is used in a larger number of applications as we
can use various cutters according to our requirements. The drawback of the
vertical milling machine is that it has low efficiency.

The vertical milling machine is again sub-divided in two types:

(a) Bed Mill: In bed mills, spindle always moves parallel to its own axis while
the table moves perpendicular to the axis of the spindle.
(b) Turret Mill: In turret mills, spindle is in stationary position and table is
moved in such a way that it will always perpendicular and parallel to the axis of
the spindle during the cutting operation.

Vertical milling machine

Horizontal Milling Machine

In a horizontal milling machine, the spindle axis is aligned horizontally. The

base of the horizontal milling machine is made up of grey cast iron. In this
machine, an arbor is used and it is inserted in a spindle nose. The gear
arrangement is inside the column. Above column, we have overarm. An arbor is
supported by yoke and arbor support. An arbor is chosen according to the
internal diameter of the cutter. Arbor and spindle both are different. Arbor is an
extension and is fitted inside the spindle and it transfers the rotational motion of
spindle to the cutter. This type of machine gives us an excellent finishing and
the cutting chips are removed easily.
 Horizontal milling machine

Universal Milling Machine

The Universal Mill is equipped with an adjustable table that allows the operator
to swivel the table to a predefined angle. Available with a turret type spindle
head or a horizontal spindle.
The machine can be produce spur, spiral, bevel gears, twist drills, reamers,
milling cutters, etc. besides doing all conventional milling operations.

Universal Milling Machine

Pedestal Grinder

These types of grinding machines are operated with electric power. This is fitted
on a pedestal frame separately on the ground. A grinder wheel is fitted each on
both sides of the shaft of the electric motor.
Tools rests are also provided with them. These are the most widely used in the
workshops. Edges of all types of cutting tools are made with these grinders.
Apart from this, molded articles can also be cleaned with it.

Pedestal Grinder

RESULT: All machine tools are thoroughly studied.

 EXPERIMENT NO.2

AIM: To Study the Capstan Lathe.

THEORY:

It is also called as ram type lathe. It carries a hexagonal turret on a ram. The ram
slides longitudinally on a saddle, poisoned and clamped on lathe bed ways. This
type of machine is lighter in connection and is suitable for machining bars of
smaller diameter. The tools are mounted on square turret. The feeding
movement is obtained when the ram moves from left to right. The capstan lathe
is so called because of the hexagon shaped tool carrier the capstan, which
replaces the tail stock of the centre lathe. The capstan (tool head) is mounted on
the capstan slide, which in turn is mounted on a suitable rest or saddle, which is
fitted on the lathe bed. The workpiece is held in the chuck at the headstock. The
capstan can usually carry six cutting tools. The construction of capstan is such
that it has a comparatively short stroke, permits rapid manipulation, especially
since the capstan head rotates automatically at the end of the withdrawal stroke,
thereby positioning a new or different tool in its holder with a minimum of lost
time, ready for performing the next operation.

Capstan Lathe
MAIN PARTS OF A CAPSTAN LATHE

Bed
The bed is a robust base that connects to the headstock and permits the carriage
and turret saddle to be aligned parallel with the axis of the spindle. This is
facilitated by hardened and ground ways which restrain the carriage and turret
saddle in a set track.

Headstock
The headstock is a large casing located at the left hand end of the bed. The head
stock of a capstan or turret lathe may be of the following types:
1. Step cone pulley driven headstock.
2. Direct electric motor driven headstock.
3. All geared headstock.
4. preoptive or preselective headstock.

Cross-slide and saddle

In small capstan lathes, hand operated cross-slide and saddle is used which are
clamped on the lathe bed at the required position. The larger capstan lathes are
equipped with usually two designs of carriage.
1. Conventional type carriage.
2. Side hung type carriage.

The Turret saddle and auxiliary slide

In a capstan lathe, the turret saddle bridges the gap between two bedways and
the top face is accurately machined to provide bearing surface for the auxiliary
slide. The hexagonal turret is mounted on the auxiliary slide. In a turret lathe,
the turret is directly mounted on the top of the saddle and any movement of the
turret is effected by the movement of the saddle. The turret is a hexagonal-
shaped tool holder intended for holding six or more tools. After one operation is
completed, as the turret is brought back away from the spindle nose, the turret
indexes automatically by a mechanism incorporated on the bed and in turret
saddle.
MECHANISM FOR CAPSTAN LATHE

TURRET INDEXING MECHANISM

Turret indexing mechanism

The turret is provided with automatic indexing mechanism. To index the turret
by 1/6 of a revolution, the ram is returned to the starting position. Then the next
tool comes into position to perform the machining operation.

Turret head, an index plate, a bevel gear and ratchet are mounted on the same
vertical spindle of the saddle. A spring-actuated plunger is used to lock the index
plate which prevents the rotation of turret during machining. When the turret
trips this stop, the plunger is released with the help of spring-loaded cam and a
pin already fitted with plunger. So, the index plate is free to rotate. Then the
indexing pawl is engaged with the ratchet and rotates 1/6 or 60֯ of revolution.
When the turret moves forward, again the plunger locks the index plate.
BAR FEEDING MECHANISM

Bar feeding mechanism

In capstan lathes, the bar is fed automatically without stopping the lathe which
reduces the production time. The bar stock passes through a chuck and hollow
spindle of the lathe. The bar is fitted with the bar chuck by setscrews.
The bar chuck rotates in a sleeve along with the bar. The loose sleeve is housed
on a sliding bracket which slides over a sliding bar. It is again attached to one
end of a chain. A suspended weight is hanging at the other end of the chain to
exert a constant force on the bar chuck towards right.
When the bar released by the collet, the force due to weight will feed the work
towards right. It continues till the work piece butts against the bar stop held in
the turret. Then the collet is closed.

ADVANTAGES:

1. A tool post turret where about 6 tools can be held with a back tool post
where an inverted tool can be used.
2. There is no lead screw here. Die head are used for cutting threads.
3. No tailstock is there, instead of that a slide and turret are provided. Turret
is generally hexagonal and is used for holding tools.
4. Provision for quick acting back gear.
5. Adjustable stops to limits the motion of saddle and turret.

RESULT: Capstan lathe has been thoroughly studied.

 EXPERIMENT NO. 3

AIM: To study the effect of cutting speed, feed, and drill diameter on the thrust
and torque in radial drilling machine.

APPARATUS: Radial Drilling machine, Different drills, Drill chuck, Drill

dynamometer.

THEORY:
The Radial drilling machine is intended for drilling medium to large and heavy
work pieces. It consists of a heavy, round, vertical column mounted on a large
base. The column supports a radial arm which can be raised and lowered to
accommodate work pieces of different heights. The arm may be swung around
to any position over the work bed. The drill head containing mechanism for
rotating and feeding the drill is mounted on the radial arm and can be moved
horizontally on the guide ways and then clamped at any desired position. These
three movements in a radial drilling machine when combined together permit
the drill to be located at any desired point on a large workpiece for drilling the
hole. When several holes are drilled on a large workpiece, the position of the
arm and the drill head is altered so that the drill spindle may be moved from one
position to another.

Cutting speed refers to the speed at which the tool point of the cutter moves with
respect to the work measured in feet per minute. Feed is the rate at which the
work moves into the cutter measured in feed per tooth revolution. Feeds and
speeds affect the time to finish a cut, tool life, finish of the machined surface,
and power required of the machine.
The cutting speed is mostly determined by the material to be cut and the material
of the tool. To calculate the proper spindle speed, divide the desired cutting
speed by the circumference of the tool (or of the part if it is rotating) expressed
in feet. The feed rate depends on the width and depth of cut, finish desired and
many other variables. To calculate the desired feed setting from the feed rate,
multiply feed per tooth per revolution by number of teeth and rpm of the
spindle.

Twist drill nomenclature

 Twist drill nomenclature

Nomenclature of Twist Drills and Other Terms Relating to Drilling

Axis: The imaginary straight line which forms the longitudinal centre line of the
drill.
Back Taper: A slight decrease in diameter from front to back in the body of the
drill.
Body: The portion of the drill extending from the shank or neck to the outer
corners of the cutting lips.
Body Diameter Clearance: That portion of the land that has been cut away so it
will not rub against the walls of the hole.
Built-Up Edge: An adhering deposit of nascent material on the cutting lip or the
point of the drill.
Cam Relief: The relief from the cutting edge to the back of the land, produced
by a cam actuated cutting tool or grinding wheel on a relieving machine.
Chip Breaker: Nicks or Grooves designed to reduce the size of chips; they may
be steps or grooves in the cutting lip or in the leading face of the land at or
adjacent to the cutting lips.
Chip Packing: The failure of chips to pass through the flute during cutting
action.
Chipping: The breakdown of a cutting lip or margin by loss of fragments
broken away during the cutting action.
Chisel Edge: The edge at the end of the web that connects the cutting lips
Chisel Edge Angle: The angle included between the chisel edge and the cutting
lip, as viewed from the end of the drill.
Clearance: The space provided to eliminate undesirable contact between the
drill and the work piece.
Clearance Diameter: The diameter over the the cut away portion of the drill
lands.
Drill Diameter: The diameter over the margins of the drill measured at the
point.
Flutes: Helical or straight grooves cut or formed in the body of the drill to
provide cutting lips, to permit removal of chips, and to allow cutting fluid to
reach the cutting lips.
Flute Length: The length from the outer corners of the cutting lips to the
extreme back end of the flutes; it includes the sweep of the tool used to generate
the flutes and, therefore, does not indicate the usable length of the flutes.
Helix Angle: The angle made by the leading edge of the land with a plane
containing the axis of the drill.
Land: The peripheral portion of the body between adjacent flutes.
Land Width: The distance between the leading edge and the heel of the land
measured at a right angle to the leading edge.
Lead: The axial advance of a leading edge of the land in one turn around the
circumference.
Lips: The cutting edges of a two flute drill extending from the chisel edge to the
periphery.
Lip Relief: The axial relief on the drill point.
Lip Relief Angle: The axial relief angle at the outer corner of the lip; it is
measured by projection into a plane tangent to the periphery at the outer corner
of the lip.
Margin: The cylindrical portion of the land which is not cut away to provide
clearance.
Point Angle: The angle included between the cutting lips projected upon a plane
parallel to the drill axis and parallel to the two cutting lips.
Shank: The part of the drill by which it is held and driven.
Tang: The flattened end of a taper shank, intended to fit into a driving slot in a
socket.

FORCE AND TORQUE IN DRILLING

Like any other metal cutting tool, when in operation, the drill is subjected to a
twisting couple ‘T’ and axial thrust ‘F’. The parameters, which influence torque
and thrust acting on a drill, are:

a) Drill diameter (d)

b) Feed, mm/rev.
c) Helix angle (ø)
d) No. of cutting edges (n)
e) Length of chisel edge (c)
f) Point angle (2σ)
g) Work material and its structure
 h) Depth of cut (d/2)
i) Cutting fluid
j) Drill sharpness

The torque acting on a drill is due to the following actions:

a) Cutting along the lips of the drill.
b) Cutting at the chisel edge, and
c) Extrusion at chisel edge.

The torque acting on the drill is determined by using the expression:

1.9 0.8
T= Cd f 1
Kg.mm
Where, C1 = constant.
For carbon steel, C1 = 33.8
For cast iron, C1 = 23.3
The thrust acting on the drill is also due to above mentioned three factors.
Thrust on the drill is given as:
F = C2 d f 0.7
Where, C2 = constant. Its value is:
C2 = 84.7 for carbon steel
C2 = 60.5 for C.I.
0.8
 
T 0.03 f  1  x  3.2 1.8
2

 x 

=

3 1.2 0.2
d (H B ) d  (1 x) 
Also,
0.8
 
F 0.55 f  1  x  2.2 0.8 2

 x  0.07 x

= +

2 1.2 0.2
d (H B ) d  (1 x) 

Where,
T = Torque, (kgf . cm) F = Thrust, kgf
D = Drill diameter, mm HB = Brinell hardness of the work material
f = feed, mm/rev x = chisel edge length / drill diameter
Observations:

L.C. of dial indicator for force =

L.C. of dial indicator for torque =

Feed = Rpm =

Drill dia. (mm) Force / Thrust (Kgf) Torque (Kgfm)

Drill dia. = Feed =

Rpm Force / Thrust (Kgf) Torque (Kgfm)

Drill dia. = Rpm =

Feed (mm/rev) Force / Thrust (Kgf) Torque (Kgfm)

Result: The Effect of Cutting speed, Feed and Drill diameter on Thrust and
Torque on Drill is studied and relevant graphs are plotted.
Discussion and Analysis:

Effect of cutting speed on thrust and torque:

As the cutting speed increases, the force also increases, but becomes nearly
constant after a certain speed. Similarly, torque also increases initially as the
speed increases, but later on it starts decreasing with further increase in the
speed.

Effect of feed on thrust and torque:

As the feed (mm/rev) given is increased, force acting on the drill also increases
linearly and hence a straight line is obtained. Similar is the case with the torque,
as the speed and feed increase, the torque also increases, though it may not be a
linear graph.

Effect of drill diameter on thrust and torque:

As the diameter of the drill increases, the force and torque both increase. Force
Vs drill diameter graph comes out to be a straight line but has less slope than
that of force Vs drill diameter graph, indicating that the increase in force due to
increase in drill diameter is more than torque.
 EXPERIMENT NO. 4

AIM: To determine Tool life of a given H.S.S. tool.

APPARATUS: H.S.S. tool, Lathe Machine, Workpiece, measuring instrument

(Tool maker’s microscope), Stop Watch.

THEORY:
A new tool has sharp cutting edges and smooth flanks. When put into operation,
it gets subjected to cutting forces that are concentrated over a relatively small
contact area on the rake face and the flank. Also, the chip slides over the rake
face and the machined surface rubs past its flank. The temperatures over the
contact surfaces are pretty high. Each time the tool enters or exits from the cut, it
is subjected to mechanical as well as thermal shock. Under such adverse
conditions, the hard tool like HSS and carbides gradually wear out and even
fracture.
There are mainly two types of tool wear:

a) Crater wear: It occurs on the rake face of the tool in the form of a pit
called as crater. The crater is formed at some distance away from the
cutting edge. Careful measurements have shown that the location of
maximum cratering and maximum chip tool interfacial temperature
coincide with each other. It may therefore be assumed that cratering is a
temperature dependent phenomenon, caused by diffusion, adhesion etc.
The crater significantly reduces the strength of the tool and may lead to its
total failure.

Regions of tool wear in metal cutting

b) Flank wear: Wear on the flank of a cutting tool is caused by friction

between the newly machined workpiece surface and the contact area on
 the tool flank. Because of the rigidity of the workpiece, the worn area,
referred to as the flank wear land, must be parallel to the resultant cutting
direction. The width of the wear land is usually taken as a measure of the
amount of wear and can be readily determined by means of a Toolmaker’s
microscope.

Development of flank wear land with time

Figure shows a typical graph of the progress of flank wear land width VB with
time or distance cut. The curve can be divided into three regions:
1. The region AB where the sharp cutting edge is quickly broken down and a
finite wear land is established.
2. The region BC, where wear progresses at a uniform rate.
3. The region CD, where wear occurs at gradually increasing rate.
Region CD is thought to indicate the region where the wear of the cutting tool
has become sensitive to the increased tool temperatures caused by the presence
of a wear land of such large proportions. Clearly, in practice, it would be
advisable to regrind the tool before the flank wear enters the last region where
rapid breakdown occurs.

Chipping: chipping refers to the breaking away of small chips from the cutting
edge of a tool or an insert on account of impact, excessive plastic deformation,
transient thermal stresses, excessive cratering and the flank wear. Chipping is
easily observed by visually examining the appearance of cutting edge and the
flank wear land. If the cutting edge appears jagged or there are cavities or
depressions in the wear land, it means the chipping has occurred. Cutting forces
of a sufficiently large magnitude may deform the cutting edge so much as to
fracture it.

High Speed Steel:

At low cutting speeds, the cutting temperatures are low. The main mode of wear
is then adhesion and abrasion. Adhesion wear is more rapid in operations
involving interrupted cuts or chatter.
At higher cutting speeds, when cutting steel and other high melting point metals,
the tool temperatures may rise above 700°C. With such high temperatures the
HSS tends to soften and plastic deformation under cutting loads becomes
possible. Crater wear also becomes pronounced on account of diffusion at the
higher temperatures.

Tool-Life Criteria
A tool life criterion is defined as a predetermined threshold value of a tool
wear measure or the occurrence of a phenomenon.

Some features of single-point-tool wear in turning operations.

Common criteria for High-Speed Steel or Ceramic Tools
The criteria recommended by the ISO to define the effective tool life for high-
speed steel tools or ceramic tools are
1. Catastrophic failure, or
2. VB = 0.3 mm if the flank is regularly worn in zone B, or
3. VBmax = 0.6 mm if the flank is irregularly worn, scratched, chipped or
badly grooved in zone B

Common criteria for Sintered-Carbide Tools

For sintered=carbide tools, one of the following criteria is recommended:
1. VB = 0.3 mm, or
2. VBmax = 0.6 mm if the flank is irregularly worn, or
 KT = 0.06 + 0.3 f, where f is the feed

Tool life:
Tool life is defined as the cutting time required to reach a tool life criterion. The
most significant factor affecting tool life when the work material, tool material,
and tool shape are chosen for a particular machining operation.

Tool life equations:

Tool life ‘T’ may be the cutting time at the end of which a tool may be termed as
unusable. A tool life equation is an empirical relationship between the tool life
and one or more variables like V, f or d.
According to Taylor’s equation:
VT n = C
Where, V = cutting velocity
n = tool life exponent.
C = Taylor’s constant
logT = 1/n logC – 1/n logV
On a log- log graph, Taylor’s tool life equation represents a straight line. If feed
and depth are also taken into account, then,
VT n f n 1 d n 2 = C1
For cemented carbide tool and steel as work material
n = 0.3
n1 = 0.31
n2 = 0.13
Factors affecting tool life:
a) Tool material: The properties of tool material which enhance its life are:
i) High hot hardness to resist deformation adhesion, abrasion
ii) Toughness
iii) Wear resistance
iv) Lack of chemical affinity with the work material
v) High thermal conductivity
vi) High specific heat
vii) Low co-efficient of Thermal expansion
b) Work material: The properties of work material that tend to increase tool
life are:
i) Softness
ii) Absence of abrasive constituents
iii) Presence of additives which help in lubrication
iv) Lack of work hardening tendency
v) Favorable micro-structure
c) Cutting Speed: High cutting speed increases tool temperature and softens
the tool material. It thereby aids abrasive, adhesive and diffusion wear. So
tool life decreases on increasing speeds as given by Taylor’s equation:
VT n = C
d) Feed: Larger the feed, greater is the cutting force per unit area of the chip
tool contact on the rake face and work-tool contact on flank face. Cutting
temperatures and therefore the different types of wear are increased.
Hence tool life decreases.
e) Depth of cut: If the depth of cut is increased, the area of the chip-tool
contact increases roughly in equal proportion to the change in depth of
cut. Consequently the rise in tool temperature is relatively small. Thus, an
increase in the depth of cut shortens tool life to some extent by
accelerating the abrasive, adhesive and diffusional types of tool wear.
f) Tool geometry: Rake angles, cutting edge angles, relief angles and nose
radius affect tool life by varying degrees. The rake angle increases when
the side rake angle or the back rake angle or both are increased. The
cutting forces, tool temperatures and tool wear decrease with increase in
the rake angle. Consequently, tool life improves when rake angles are
increased. However, larger rake angles make the cutting edge sharper and
reduce its mechanical strength making the tool liable to chipping.
Therefore, there is an optimum rake angle associated with every tool-
work pair.
g) Cutting fluid: Cutting fluid lowers the cutting temperature, and hence
decreases the wear and increase tool life of the tool.
 PROCEDURE:

1. Make a mark on measuring device where the cross bar point and tool
point coincide. Now relative to this mark, all the readings will be taken.
2. Perform a turning operation on the lathe tool, using this HSS tool for
about one minute.
3. After doing this remove the burrs from the tool using grinding wheel.
4. Put the tool again on the measuring instrument and adjust, in such a way
that the tool point again coincide with cross bar point.
5. Repeat step (2) to (4) for two minutes and three minutes machining
time.
6. Find the tool life.
7. Using Taylor’s equation, plot the log-log graph.

OBSERVATION:

L.C of cross dial =

RPM =
Feed =
Diameter =
Depth of cut =
L.C of micrometer =
Initial reading =
Workpiece material = Mild steel
Tool Material = HSS

Time MSR VSR Total Difference Wear

S. No.
elapsed (cm)
1.

2.

3.

4.

5.

6.
RESULT:

Tool life phenomenon for a HSS tool has been thoroughly studied. The graph
between Wear and Time has been plotted.

DISCUSSION AND ANALYSIS:

The progress of flank wear during machining is characterized by three stages:

1. The initial breakdown stage, where the sharp cutting edge is rapidly
broken down and a tool wear land of finite dimensions established.
2. The middle stage, where wear occurs at a uniform rate.
3. The final rapid breakdown stage, where it is thought, the tool wears at an
increasing rate due to rapidly increasing temperatures generated by
friction between the flank wear land and transient surface on the
workpiece.
 EXPERIMENT NO. 5

AIM: To study and find out the effect of change in cutting speed, feed and depth
of cut on the cutting force and the feed force while turning using a lathe tool
dynamometer.

APPARATUS: Lathe Machine, Lathe Tool Dynamometer, Workpiece etc.

THEORY
A dynamometer is a machine used to measure torque and rotational speed (rpm)
from which power produced by an engine, motor, pump or other rotating prime
mover can be calculated. In order to put the analysis of the metal cutting
operation on a qualitative basis, certain observations must be made before,
during and after a cut. Design criteria will be discussed. first, followed by a
review of several types of force measuring equipments. Hence, it is essential to
study the metal cutting process for economical aspects of the manufacture of the
components.

DYNAMIC FORCE MEASUREMENT- Tool dynamometers have some

additional difficulties since these generally measure orthogonal forces by using
electrical dynamometer which involve the use of transducers. The changes in
electrical signals are indirectly produced by the tool forces by causing strain or
displacement. Also, electric transducer works on the principle of Wheatstone
Bridge Circuit. It is evident that in order to measure the strains of the order of 1
in/in., the strain gauge lathe dynamometer is used. It is frequently convenient to
reduce the lathe operation to a two dimensional process. While any two force
components may be measured, the most convenient are the axial and the
tangential components of force will cause a bending moment at some distance
from the cutting edge that will cause a moment on the beam tends to measure
the lathe forces.

Procedure
Cutting force have been measured by using the lathe tool dynamometer (Integral
damping by heavy cast iron body) which suit to a wide range of lathes and easily
fixed to lathe cross slide. By the application of cutting tool theory, the effect of
various parameters such as cutting speeds, feed and cutting forces on the action
of cutting tool by varying the depth of cut has been observed.
1. Measurement of cutting force by using electrical strain gauge is the best
technique available.
2. The machining parameters will be considered during the machining w.r.t.
cutting forces and feed forces by predicting the cutting performance such as
depth of cut, feed/rev. and speed.

Observations:

Work material =
Tool material =
Dia of work piece =

Feed = Rpm =
Depth of cut (mm) Cutting Force (N) Feed force (N)

Depth of cut = Feed =

Rpm Cutting Force (N) Feed force (N)

Depth of cut = Rpm =

Feed (in/rev) Cutting Force (N) Feed force (N)
Result and Discussion:

Effect of Depth of cut on cutting force and the feed force: When feed and
speed of turning tool is kept constant, with the increase in Depth of cut, both
cutting force and feed force increases.

Effect of speed on Cutting force and the feed force: When feed and depth of
cut of turning tool is kept constant, with the increase in speed, feed force
increases whereas cutting force first decreases to its minimum value i.e. 21 at
190rpm and then increases.

Effect of feed on cutting force and the feed force: When speed and depth of
cut of turning tool is kept constant, both cutting force and feed force first
increases and then decreases.
 EXPERIMENT NO. 6

AIM: To study the effect of cutting speed, feed, depth of cut and rake angle on
cutting ratio and shear angle.

APPARATUS: Lathe, Vernier caliper, Cutting tool, Thread, Ruler.

THEORY: Irrespective of basic nature of the chip obtained during machining

of metal, the main factor governing the formation of chips is the plastic
deformation of the metal by a shear process. The deformation of metal occurs
along a plane just ahead of the tool and running upto free work surface. After
passing out the shear plane, the deformed metal slides along the tool face due to
the velocity of cutting tool. The size of the shear zone is thick if the metal is
machined at low cutting speed and vice versa.
During orthogonal cutting, the tool moves with a velocity V c against the work,
thereby shears the metal along the shear plane AB. The out coming chip of
thickness t2 experiences two velocity components, Vf and Vs along the tool face
and shear plane. The undeformed chip thickness is t1 which is actually the feed
in certain machining operations. From the above configuration it is possible to
compute the value of shear angle (  ) in terms of measurable parameters t1, t2 and
.

Geometry of chip formation

From the right angled triangle,  ABC,

AB  t 1

sin 
Where, Shear angle
Further, from the right angled triangle, ABD,
Sin (90-  +  ) = t 2

AB

AB = t 2

Sin(90     )

AB = t 2

Cos(   )

Where,  = rake angle.

t 1
= t 2

Sin  Cos(   )

t Sin
1
=
t 2
Cos(   )

Sin
r =
C
Cos(   )

Sin
r =
C
CosCos  SinSin

1 CosCos  SinSin
=
r c
Sin

1
= CosCot  Sin
r c

Where r
= cutting ratio
C
Cos
tan  = r c
1  r c Sin

The chip thickness ratio can also be expressed in a different way. Let l2 length of
the cut chip which had a length l1 before cutting. As the volume remains
constant, it may be written that

l1 t1 b1 = l2 t2 b2
Where bl is width of cut b2 is the width of chip.
When, there is no side flow of metal then b1 = b2.
l2 x t2 = l1 x t1

or l2/l1 = t1/t2

PROCEDURE:

1) Perform a turning operation on Lathe using a sharp tool, perform

orthogonal cutting.

2) Obtain the chip produced.

3) With the help of a thread and a ruler measure its length.

4) Using a Vernier find its breadth.

5) Calculate tl /t2 using above given relations, hence find rc.

6) Calculate using,
1  r c Cos 
 = tan  
1  r c Sin  

7) Perform the above steps at different speeds, feed, and depth of cut.

OBSERVATION:

Diameter of workpiece, D =
Slot width =
L1 = π D-slot width
Feed =
Rake angle (  ) =
When L1= Depth of cut =
N(rpm) L2(cm) rc =L2/ L1 Φ
1
2
3

When L1= N (rpm) =

Depth of cut(div) L2(cm) rc =L2/ L1 Φ
1
2
3

When L1= Depth of cut =

Feed L2(cm) rc =L2/ L1 Φ
1
2
3

RESULT: The effect of Cutting Speed, Feed, Depth of cut, and Rake angle on
Cutting Ratio rc and Shear angle  has been studied.

DISCUSSION AND ANALYSIS:

EFFECT OF CUTTING SPEED: The cutting ratio increases as the cutting

speed is increased. The chip becomes thinner and area of shear plane is reduced.
The forces required to produce the chip becomes smaller as cutting speed is
increased. So, as the cutting speed is increased, specific cutting energy reduces,
resulting in higher efficiency.

EFFECT OF FEED: At larger feeds, the specific cutting energy ps and shear
strength of the work material s remains constant, but at low feeds, ps and s both
increase. This is due to “tool-nose” force.

EFFECT OF RAKE ANGLE: As the rake angle increases the shear angle also
increases. The specific cutting energy ps reduce as rake angle  increases. This
results in greater efficiency at larger value of rake angle. The friction angle 
also increases as rake angle is increased. As  increases, the stress at the tool
chip interface decrease and since frictional stress remains constant, increases.
 EXPERIMENT NO. 7

AIM: To Study CNC Turning Centre.

Principle of CNC Operation

The following are the principles of CNC operation:
 Movement of X, Y, and Z axis are controlled by motor which supplies
either alternating current or Direct current.
 Movement of machine is done by giving commands.
 All the operations are carried out by codes like speed, feed, depth of cut,
etc.
 For each operation separate code is available.
 Warning system is available to save guard the various operations and
components.

The main parts of the CNC machine are

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.

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.
 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.

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 are controlled in the Z axis direction.
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.

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.

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

CNC Lathe Main Parts

Headstock
Headstock of a cnc lathe machine has the main motor of cnc lathe machine
which drives the main spindle. Chuck is mounted on this main spindle.

CNC Lathe Bed

The tool turret travel over the cnc lathe bed, which is specially hardened so any
kind of machining can’t affect them.

Chuck
CNC lathe machine chuck grips the components which are to be machined.
Chuck itself has many parts. Jaws are mounted on the chuck to grip the part.

Tailstock
Tailstock is mostly used to give an extra gripping force for component
machining. For long components machining they provide extra force on the
other end so machining process can complete smoothly.
Foot Switch or Foot Pedals
Through these pedals, open and close the chuck to grip the component, the same
way tailstock quill is taken to forward position or reversed through theses
pedals.

CNC Control Panel

The brain of the CNC machine, all the CNC program are stored inside this
panel, the whole machine is controlled through the keys on this panel. To start or
stop the machine, move axis by pressing different keys on this panel, enter new
program by using this panel, programs can be transferred by using USB port on
this panel as well. So this is the main part which controls the whole CNC
machine.

Tool Turret
The tools are mounted on the tool turret which are used for component
machining. Tool turrets vary in shapes and number of tools that can be mounted
on them.

How CNC Machine Works

 First the part program is inserted into the MCU of the CNC.
 In MCU all the data process takes place and according to the program
prepared, it prepares all the motion commands and sends it to the driving
system.
 The drive system works as the motion commands are send by MCU.
Drive system controls the motion and velocity of the machine tool. .
 Feedback system, records the position and velocity measurement of the
machine tool and sends a feedback signal to the MCU.
 In MCU, the feedback signals are compared with the reference signals and
if there are errors, it corrects it and sends new signals to the machine tool
for the right operation to happen.
 A display unit is used to see all the commands, programs and other
important data. It acts as the eye of the machine.

Advantages
 It can produce jobs with highest accuracy and precision than any other
manual machine.
 It can be run for 24 hours of a day.
  The parts produced by it have same accuracy. There is no variation in the
parts manufactured by a CNC machine.
 Highly skilled operator is not required to operate a CNC machine. A
semi-skilled operator can also operate accurately and more precisely.
 Operators can easily make changes and improvements and reduces the
delay time.
 It has the capability to produce complex design with high accuracy in
minimum possible time.
 The modern design software, allows the designer to simulate the
manufacturer of his/her idea. And this removes the need of making a
prototype or model and saves time and money.
 Fewer workers are required to operate a CNC machine and saves labour
cost.

Disadvantages
Despite of having so many advantages, a CNC machine has some disadvantages
too. And these are:
 The cost of the CNC machine is very high as compared with manually
operated machine.
 The parts of CNC machines are expensive.
 The maintenance cost in the case of CNC is quite high.
 It does not eliminate the need of costly tools.

Applications
Almost every manufacturing industry uses CNC machines. With increase in the
competitive environment and demands, the demand of CNC usage has increased
to a greater extent. The machine tools that come with the CNC are lathe, mills,
shaper, welding etc. The industries that are using CNC machines are automotive
industry, metal removing industries, industries of fabricating metals, electrical
discharge machining industries, wood industries etc.

CNC Lathe G Code List

List of G-codes commonly found on Fanuc and similarly designed CNC controls
are:

G code Description
G00 Rapid traverse
G01 Linear interpolation
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G09 Exact stop
G10 Programmable data input
G20 Input in inch
G21 Input in mm
G22 Stored stroke check function on
G23 Stored stroke check function off
G27 Reference position return check
G28 Return to reference position
G32 Thread cutting
G40 Tool nose radius compensation cancel
G41 Tool nose radius compensation left
G42 Tool nose radius compensation right
G70 Finish machining cycle
G71 Turning cycle
G72 Facing cycle
G73 Pattern repeating cycle
G74 Peck drilling cycle
G75 Grooving cycle
G76 Threading cycle
G92 Coordinate system setting or max. spindle speed setting
G94 Feed Per Minute
G95 Feed Per Revolution
G96 Constant surface speed control
G97 Constant surface speed control cancel
CNC Lathe M Code List

M code Description
M00 Program stop
M01 Optional program stop
M02 End of program
M03 Spindle start forward CW
M04 Spindle start reverse CCW
M05 Spindle stop
M08 Coolant on
M09 Coolant off
M29 Rigid tap mode
M30 End of program reset
M40 Spindle gear at middle
M41 Low Gear Select
M42 High Gear Select
M68 Hydraulic chuck close
M69 Hydraulic chuck open
M78 Tailstock advancing
M79 Tailstock reversing
M94 Mirror image cancel
M95 Mirror image of X axis
M98 Subprogram call
M99 End of subprogram

Result: CNC Turning Centre is thoroughly studied.

 EXPERIMENT NO. 8

AIM: To perform operation in CNC Turning Centre.

EQUIPMENT: - CNC turning centre, Turning tool, M.S or Al. as a work piece
material.

PROCEDURE:-
Choose work piece material as Al, M.S etc and work piece diameter of about 40
mm and hold the work piece on chuck so that about hundred mm length is
available for turning. Choose the suitable cutting speed and find cutting velocity
from V= πDN

The basic CNC machining process includes the following stages:

 Designing the CAD model
 Converting the CAD file to a CNC program
 Preparing the CNC machine
 Executing the machining operation

Once the CAD design is completed, export it to a CNC-compatible file format.

The formatted CAD design file runs through a program, typically computer-
aided manufacturing (CAM) software, to extract the part geometry and
generates the digital programming code which will control the CNC machine
and manipulate the tooling to produce the custom-designed part.

CNC machines used several programming languages, including G-code and M-

code. The most well-known of the CNC programming
languages, general or geometric code, referred to as G-code, controls when,
where, and how the machine tools move e.g., when to turn on or off, how fast to
travel to a particular location, what paths to take, etc. across the workpiece.
Miscellaneous function code, referred to as M-code, controls the auxiliary
functions of the machine, such as automating the removal and replacement of
the machine cover at the start and end of production, respectively.

Once the CNC program is generated, load it to the CNC machine.

Machine Setup
Before running the CNC program, we must prepare the CNC machine for
operation. These preparations include affixing the workpiece directly into the
machine, onto machinery spindles, or into machine vises or similar work
holding devices, and attaching the required tooling, such as drill bits and turning
tools, to the proper machine components/ tool posts.
Once the machine is fully set up, we can run the CNC program.

Machining Operation Execution

The CNC program acts as instructions for the CNC machine; it submits machine
commands dictating the tooling’s actions and movements to the machine’s
integrated computer, which operates and manipulates the machine tooling.
Initiating the program prompts the CNC machine to begin the CNC machining
process, and the program guides the machine throughout the process as it
executes the necessary machine operations to produce a custom-designed part or
product.

SPECIFICATION:
DESCIPTION UNIT
CAPACITY TAILSTOCK
Swing Over bed mm 510 Quill dia mm 75
Chuck dia. Max mm 210 Quill stroke mm 100
Max. Turning dia mm 320 Quill taper Type MT-4
Max. Turning Length mm 310
Admit Between Centres mm 440

SPINDLE CNC SYSTEM

Spindle nose type A2-6 Controller Type Fanuc
Hole through spindle mm 61
Spindle speed rpm 3500
Spindle motor power kW 9/11

FEED
Inclination of Carriage Deg 30° to Horizontal Plane
Travel X - Axis mm 185
Travel Z - Axis m/min 370
Rapid traverse (X/Z) Axes m/min 30 / 36

MACHINE SIZE
LxBxH mm 2065 x 1925 x 1680
Weight Kg 3500

TURRET
No. of stations nos. 8
Tool shank size mm 25 x 25
Max. Boring bar dia mm 40
Turret Indexing type Hydraulic
Turret indexing time sec 0.8 to 1
Sample program: (Turning)

%
O0027 (Turning)
N1
G28U0.0
G28W0.0
T0202
G97S1500M3
G0X45.0Z10.0
Z3.0
G90X72.0Z-65.0F.15
X40.0
X39.0
X38.0
G0X42.0Z2.0
G28U0.0
G28W0.0
M30
%

Sample program: (Facing)

%
O0025 (Facing)
N1
G28U0.0
G28W0.0
T0707
G97S1000M3
G0X45.0Z10.0
Z5.0
G94X-2.0Z2.0F.15
Z1.5
Z1.0
Z0.5
Z0.0
G28U0.0
G28W0.0
M30
%

RESULT:
 EXPERIMENT NO. 9

AIM: To study CNC Vertical Milling Centre.

THEORY
VMC machining refers to machining operations that utilize vertical machining
centers (VMCs), which, as the name suggests, have vertically oriented machine
tools. These machines are primarily utilized to turn raw blocks of metal, such as
aluminum or steel, into machined components. They can be used to perform a
variety of machining operations, including, but not limited to, the following:
cutting, drilling, tapping, countersinking, chamfering, carving, and engraving.
This versatility, combined with their relatively low cost, has made them a highly
common machine shop tool.

VMC main parts:

Rotating Spindle: The Spindle, which is perpendicular to the working surface

or table, can hold a variety of cutting tools (or mills as they are sometimes
called). The spindle cartridge is mounted in a housing that moved up and down -
this direction of motion is called the Z-Axis.

Table: The Table is a platform on which to mount workpieces - either directly

or through a variety of fixtures like milled aluminum plates or hard clamping
vises. The table has a motion of left and right, which we call the X-Axis, and
front to back, which is called the Y-Axis. These two axes of motion, coupled
with the Z-Axis, allow for virtually unlimited contouring across the planes of
motion.

Tool Changer: A tool changer greatly increases a VMC's productivity by

allowing for the automatic, computer-controlled selection of tools for a variety
of tasks from rough cutting to fine hole boring.

Coolant System: To keep parts and cutters cool and lubricated, most VMCs
employ some sort of recirculating coolant system; which is usually a mix of
soluble oil and water but can be a variety of other liquids as well.

Chip/Screw Conveyor: To evacuate the chips from the work zone, a variety of
chip conveyors and chip augers may be employed to increase productivity and
reduce downtime from manually shoveling out waste chips.
Full Covers/Enclosures: These can be added to reduce the splash/splatter
caused by milling operations and protect the operators and environment from the
machining process.

Rotating Tables: Adding additional Axes to the machine can greatly increase
its productivity by turning a simple three-axis machine into a four- or even five-
axis system capable of machining complex components with varying surfaces
(such as turbine blades).

Quick Loading Loaders: Another great addition to significantly increase

productivity is the use of shuttle tables or other automatic part loading systems.
These can decrease downtime and greatly increase the spindle “ON” time of
most VMC systems.

Advantages of VMC Machining

Compared to horizontal machining centers, vertical machining centers offer a
number of advantages, such as:

 Simpler structure: The simple structure of VMCs makes it easy to clamp

the workpiece in the necessary position.

 Better cooling efficiency: Gravity works with the VMC design. Coolant
sprayed at the top of the machine tool and workpiece trickles down to
cover the rest of the target.

 Easier setup and operation: VMCs have a wide field of vision, enabling
operators to observe the operations and, if needed, make modifications to
resolve any issues.

 Smaller space requirements: The vertical design takes up less floor

space than a horizontal design.

 Higher accuracy: VMCs can produce complex shapes and structures

with a high degree of accuracy.
Applications of VMC Machining
Vertical machining centers can be used to manufacture parts and products for a
wide range of industries and applications. However, they are primarily used for
high-precision, high-accuracy, and mass-production projects, including those
involving the following machined components:

Complex curved parts: Examples of parts with complex curves include cams,
impellers, and propellers. While these parts are difficult to manufacture with
precision and accuracy using conventional machining methods, a multi-axis
VMC with CNC technology can produce them easily and quickly.

Special or irregularly shaped parts: Examples of parts with irregular or

special shapes include brackets and bases. These components often have highly
complex designs, which are hard to produce using other manufacturing methods
but easy to produce using VMCs with automatic machining capabilities.

Military parts: The military industry is subjected to a variety of standards that

dictate how a part can be designed and built. The accuracy and precision of
VMCs ensure the machined components produced fully meet the necessary
application and industry specifications.

CNC Milling G Code List

G code Description
G00 Rapid traverse
G01 Linear interpolation
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G17 X Y plane selection
G18 Z X plane selection
G19 Y Z plane selection
G28 Return to reference position
G30 2nd, 3rd and 4th reference position return
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation + direction
G44 Tool length compensation – direction
G49 Tool length compensation cancel
G53 Machine coordinate system selection
G54 Workpiece coordinate system 1 selection
G55 Workpiece coordinate system 2 selection
G56 Workpiece coordinate system 3 selection
G57 Workpiece coordinate system 4 selection
G58 Workpiece coordinate system 5 selection
G59 Workpiece coordinate system 6 selection
G68 Coordinate rotation
G69 Coordinate rotation cancel
G73 Peck drilling cycle
G74 Left-spiral cutting circle
G76 Fine boring cycle
G80 Canned cycle cancel
G81 Drilling cycle, spot boring cycle
G82 Drilling cycle or counter boring cycle
G83 Peck drilling cycle
G84 Tapping cycle
G85 Boring cycle
G86 Boring cycle
G87 Back boring cycle
G88 Boring cycle
G89 Boring cycle
G90 Absolute command
G91 Increment command
G92 Setting for work coordinate system or clamp at maximum spindle speed
G98 Return to initial point in canned cycle
G99 Return to R point in canned cycle
CNC Milling M Code List

M code Description
M00 Program stop
M01 Optional program stop
M02 End of program
M03 Spindle start forward CW
M04 Spindle start reverse CCW
M05 Spindle stop
M06 Too change
M07 Coolant ON – Mist coolant/Coolant thru spindle
M08 Coolant ON – Flood coolant
M09 Coolant OFF
M19 Spindle orientation
M28 Return to origin
M29 Rigid tap
M30 End of program (Reset)
M41 Low gear select
M42 High gear select
M94 Cancel mirror image
M95 Mirror image of X axis
M96 Mirror image of Y axis
M98 Subprogram call
M99 End of subprogram

Result: CNC Vertical Milling Centre is thoroughly studied.

 EXPERIMENT NO. 10

AIM: To perform operation in CNC Vertical Milling Centre.

LINEAR INTERPOLATION
CODE USED: - G01
FORMAT: - G01 X_ Y_ Z_ F_
X,Y CO-ORDINATE (DISTANCE TO GO)
Z – DEPTH OF CUT
F- FEED RATE (IN MM/MIN)

DRAWING

X Y

20 20

20 80

80 80

80 20
STANDARD FORM OF A PROGRAM

Four segments of a CNC Program:-

1. Start up Program.
2. Tool Position Program.
3. Profile Program.
4. End of Program.

1. Start up Program.

G21 G94
G91 G28 Z0
G28 X0 Y0
M06 T1
M03 S2000

2. Tool Position Program

G90 G00 X20 Y20

Z10

3. Profile Program

G01 Z-1 F60

X20 Y80
X80 Y80
X80 Y20
X20 Y20
G00 Z10

4. End of Program

G91 G28 Z0
G28 X0 Y0
M05
M30
CIRCULAR INTERPOLATION

CODE USED: - G02/G03

FORMAT:- G02/ G03 X_ Y_ Z_ R_ F_
X, Y- CO-ORDINATE
Z- DEPTH OF CUT
R- RADIUS
F- FEED RATE

DEPTH OF CUT- 1MM

DIA OF SLOT- 6 MM
PROGRAM
G21 G94
G91 G28
G28 X0 Y0 Z0
M06 T1
M03 S2000
G90 G00 X-30 Y0
Z10
G01 Z-1 F30
G02 X30 Y0 R30 F30
G02 X-30 Y0 R30
G00 Z10
G91 G28 X0 Y0
G28 Z0
M05
M30
Combination of circular and linear interpolation

PROGRAM
G21 G94
G91 G28 Z0
G28 X0 Y0
M06 T1
M03 S2000
G90 G00 X-15 Y-25
Z10
G01 Z-1 F30
G01 X15 F60
G03 X25 Y-15 R10
G01 Y15
G02 X15 Y25 R10
G01 X-15
G03 X-25 Y15 R10
G01 Y-15
G01 X-15 Y-25
G00 Z10
G91 G28 Z0
G28 X0 Y0
M05
M30

SUB- PROGRAM
CODE USED-M98 P000øøøø
M99
M98- SUB-PROGRAM CALL
M99-RETURN TO MAIN PROGRAM
000 – NUMBER OF REPEAT
øøøø - PROGRAM NUMBER

G21 G94
G91 G28 Z0
X0 Y0
M06 T1
M03 S2000
G90 G00 X20 Y20
Z10
G01 Z0 F60
M98 P0059999
G01 Z10
G91 G28 X0 Y0 Z0
M05
M30
O9999
G91 G01 Z-1F60
G90 X20 Y80
X80 Y20
X20 Y20
M99

RESULT: