Training PPT on CNC MACHINES

1. 1INDUSTRIAL TRAINING
ON
CNC MACHINES
UNDER THE GUIDANCE OF
Er. Sanjay Jindal (DGM Maintenance)
Submitted By: Er. Sahil Gupta
Roll NO: 2110003

2. 2CNC Machines
Computer Numerical control (CNC) is the Automation
of Machine Tools that are operated by abstractly
programmed commands encoded on a storage medium,
as opposed to controlled manually via hand wheels or
levers, or mechanically automated via cams alone.
Modern CNC systems, end-to-end component design is
highly automated using Computer-aided Design (CAD)
and Computer-aided Manufacturing (CAM) programs.
The programs produce a computer file that is interpreted
to extract the commands needed to operate a particular
machine via a postprocessor, and then loaded into the
CNC machines for production.

3. Basic CNC Principle
All computer controlled machines are able to accurately and repeatedly control
motion in various directions. Each of these directions of motion is called an
axis. Depending on the machine type there are commonly TWO to FIVE axes.
X,Y,Z – Axis
Cartesian Coordinate System
X,Y,Z,A,B – Axis
CNC Coordinate System
A: Rotary axis along X - Axis
B: Rotary axis along Y - Axis

4. 4
Key Concept
Number One
CYCLE
START
FEED
HOLD
EDIT
AUTO
MDI JOG
HANDLE
ZERO
RETURNMODE
0%
100%
200%
FEEDRATE
OVERRIDE
10%
25% 50%
100%
RAPID
OVERRIDE
1
12
TURRET INDEX
2
3
4
5
6
7
8
9 10 11
SLOW FAST
EMERGENCY
STOP
FANUC 10T
POWER
ON
OFF
O N G P A
X Y Z Q B
I J K R C
F D H L #
M S T /EOB
U V W
Sp
E ? @ @
,
[ ] ( )
*
PAGE CURSOR
SHIFT
7 8 9
4 5 6
1 2 3
- 0
+ = CAN
RESET
START
CALC
INPUT
NC/PC
AUX
X00.0000
Z00.0000
X Z
X1
X10
X100
0
ON
OFF
DRY
RUN
SINGLE
BLOCK
MACHINE
LOCK
OPTIONAL
STOP
BLOCK
DELETE
X+
X-
Z-
JOYSTICK
Z+
ON OFF
SPINDLE
ORIGIN
X Z
0%
100%
130%
SPINDLE LOAD
0%
100%
130%
AXIS LOAD
X Z
OD ID
CLAMP
DIRECTION
OFF ON
MEMORY
PROTECT
CHUCK TAILSTOCK
Key concept #2
From programmer’s viewpoint
You must understand the
machine you’ll be working with!
From operator’s viewpoint
Key concept #1
In key concept #2 we look at the
machine from a programmer’s viewpoint
In key concept #1 we look at the
machine from an operator’s viewpoint

5. 5
Machine Configurations
(2-axis Only)

6. Front view of machine

7. Headstock
& Spindle Work-holding
Device
Job
Tailstock
Body
Center
Turret

8. 8
N0020: Instruction Number
G00: Tool Not at Home position
G57: Rotation of axis after tool base position
S500: Speed of Rotation 500Rpm
M04: Bypass Flag OR alarm
Operator’s Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

9. Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

10. 10
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

11. 11
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

12. 12
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

13. 13
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

14. 14
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

15. 15
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

16. 16
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

17. 17
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

18. 18
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

19. 19
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

20. 20
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

21. 21
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

22. 22
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

23. 23
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

24. 24
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

25. 25
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

26. 26
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

27. 27
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

28. 28
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

29. 29
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

30. 30
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

31. 31
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

32. 32
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

33. 33
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

34. 34
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

35. 35
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

36. 36
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

37. 37
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

38. 38
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

39. 39
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

40. 40
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

41. 41
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

42. 42
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

43. 43
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

44. 44
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

45. 45
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

46. 46
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

47. 47
Z Axis- +
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

48. 48
Z Axis- +
Z is the length controlling axis
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

49. XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

50. 50
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

51. 51
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

52. 52
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

53. 53
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

54. 54
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

55. 55
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

56. 56
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

57. 57
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

58. 58
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

59. 59
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

60. 60
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

61. 61
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

62. 62
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

63. 63
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

64. 64
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

65. 65
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

66. 66
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

67. 67
XAxis
-
+
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

68. 68
XAxis
-
+X is the diameter controlling axis
Instruction :
N0020 G57 G00 X3.0 Z3.5 S500 M04

69. XAxis
-
+
3.000
X3.0
If you want to turn a 3.0 inch diameter…
X3.0 will be the commanding word
3.500
If you want to turn a 3.5 inch Length…
will be the commanding word
Z3.5

70. Programmer’s View
First motive of the programmer
is to get the machine ready for
production by changing the
current program and then
analyse the problem in the
machine due to which the
breakdown occurs.

71. 71
ATC NOT WORKING
STAGE – 1 : Check the Problem using CNC Ladder Logic
Input of “Tool arrived” is not coming.
a)Check the tool position
b)Fix tool in pocket
c)Check other conflicts
d)Bypass the input X067
e)Look over the process for one
cycle
f)Handover the machine to Operator.
Result : Machine is ready for
production
STAGE – 2 :
Find Actual Cause of Problem
STAGE -3 : STAGE – 4 :
KAIZEN POKA YOKE
STAGE – 5 : STAGE - 6
WHY – WHY ? FAULT TREE

72. 72
INITIAL: X067 is NO
Cause : Limit Switch input is missing
ACTION : Bypass X067 (say with M054 NC)
Result : Tool Clamped

73. 73
STAGE – 2 : Actual Cause of Problem
a) Limit Switch input missing
b) PDB Not Working
c) Strobe Length Increased
d) Nut Opened.
STAGE – 3 : KAI ZEN - Change For Better
Limit Switch Proximity Switch
REPLACED
a) Increased Performance
b) Reliability
c) Life about 15years
d) Delay Decreased
e) Easy to replace

74. 74
STAGE – 4 : POKA-YOKE Mistake-Proofing
BEFORE AFTER
This mechanism in a
manufacturing process is that
which helps an equipment
operator to avoid (YOKE)
mistakes (POKA). The
purpose is to eliminate
product defects by preventing
, correcting , or drawing
attention to human errors as
they occur.
Using one NUT make the length of strobe increased on prolong use. Bt
using two NUTs, one after other make it fix for long use which reduces
human as well as mechanical errors. This helps in reducing required
maintenance.

75. 75STAGE – 5 WHY –WHY ?

76. 76STAGE –6 FAULT TREE

78. 78
Name :- Sahil Gupta
Roll No. :- 2110003
Branch :- E.C.E.