Basic Training Programme on CNC Turning and Machining Centre for SJ

Government Polytechnic Students (VMC & HMC)

25th - 26th February 2014

& 10th - 11th March 2014

UNIDO - ICAMT, Bangalore

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CONTENTS Topic Pg no

1. Introduction 3 2. Objectives 3 3. Training Method 3 4. Agenda 4 5. Summary of Proceedings –

Turning Centre - 25 & 26 February 2014 Machining Centre -10-11 March 2014

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6. List of Participants 25 & 26 February 2014 8 7. List of Participants 10-11 March 2014 11 8. Benefits 9. Feedback Analysis 11 10. Registration Sheet Annexure 1 11. Course Material Annexure 2 12. Feedback Forms Annexure 3

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Introduction The International Centre for the Advancement of Manufacturing Technology is an International Technology Centre of the United Nations Industrial Development Organization. ICAMT has been set up in cooperation with the Government of India for promoting manufacturing technologies and innovations as a means to deliver industrial competitiveness in developing countries.

CNC Technology, be it as a Product or a manufacturing practise, is an integral part of manufacturing technology across the spectrum of Industries, be it small, Medium or Large. The subject is also being taught at Polytechnic Course level. Although, the workshops at the Polytechnics do have CNC Machines and equipments for Demonstrations, they do not have adequate expertise to train students to understand, feel and see CNC Machines working in the shops. With a view to make the students to get first-hand experience of the use / application and to make them enthused to look at Manufacturing as a future career option, UNIDO – ICAMT has launched this unique initiative – Institution –Academician Interface for making apprentice industry ready through knowledge transfer / awareness creation of CNC Machining in shop environment.

Objectives The objective of the training was to provide basic knowledge on CNC machining, tooling, cutting parameters, process planning, CNC part programming, machine setting, work holding and troubleshooting with emphasis on efficient metal cutting techniques and best shop floor practices. More importance was given to efficient programming, problem solving techniques, tools and cutting parameters.

Training Method Before the training was conducted a comprehensive approach was undertaken to understand specific requirements of Polytechnic students. The Faculty collected data about their requirements and prepared the course material to conduct the 2 days+2days training program on CNC Turning & Machining center (VMC &HMC).

The training included classroom lecture sessions, simulation and learning through the CAD CAM software. Participants also had the opportunity to incorporate their learnings through actual hands-on working on the virtual CNC Turning & Milling software. The classroom lectures were supported by multimedia presentation and interactions with frequent question

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and answer sessions. Sessions on machining strategy were taught by using the CAD (Computer Aided Design) CAM (Computer Aided Manufacturing) software at ICAMT which was followed by group exercises and problem solving to ensure their understanding.

Agenda

Basic Training Programme on CNC Turning Centre for SJ Government Polytechnic Students

25-26 February 2014

Day 1: 25th Feb 2014, Venue 09.30 am - 10.00 am Registration

UNIDO ICAMT,

Tumkur road Bangalore

10.00 am - 10.30 am Knowledge inventory – Oral introduction 10.30 am - 11.00 am Introduction Turning Centers

Machining operations 11.00 am - 11.15 am Break 11.15 am - 01.30 Cutting tools and its applications

Cutting parameters & Calculations G-codes & M-codes & Program format

01.30 pm - 02.15 pm Break 02.15 pm - 03.00 pm Programming concepts for General turning,

Grooving, Threading and Drilling operations 03.00 pm - 03.15 pm Break 03.15 pm - 05.00 pm CAD CAM Practice

Day 2: 26th Feb 2014, Venue

09.30 am - 01.00 pm Part Programming and CAD CAM practices

UNIDO ICAMT Tumkur road

Bangalore

01.00 pm - 01.45 pm Break

2.00pm - 05.30 pm

Hands on session: Turning Center (Fanuc control) Machine setting (work holding, Tool offsets) Program edit Machining test part in Simulator

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Basic Training Programme on CNC Machining Centre for SJ Government Polytechnic Students

10-11 March 2014 Day 1: 10th Mar 2014 Venue 09.30 am - 10.00 am Registration

UNIDO ICAMT, Tumkur road

Bangalore

10.00 am - 10.30 am Knowledge inventory – Oral introduction 10.30 am - 11.00 am Introduction Machining Centers

Machining operations 11.00 am - 11.15 am Break 11.15 am - 01.30 Cutting tools and its applications

Cutting parameters & Calculations G-codes & M-codes & Program format

01.30 pm - 02.15 pm Break 02.15 pm - 03.00 pm Programming concepts for Face milling, Side

milling, Hole machining(Drilling, Boring, Tapping) operations

03.00 pm - 03.15 pm Break 03.15 pm - 05.00 pm CAD CAM Practice

Day 2: 11th Mar 2014 Venue

09.30 am - 01.00 pm Part Programming and CAD CAM practices

UNIDO ICAMT Tumkur road

Bangalore

01.00 pm - 01.45 pm Break

2.00pm - 05.30 pm

Hands on session: Machining Center (Fanuc control) Machine setting (work holding, Tool offsets) Program edit Machining test part on Simulator

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Summary of Proceedings Two day+ two day Training on CNC Part Program on Turning & Machining centers for 57 final year students of S. J. (Govt) Polytechnic of Bangalore was conducted at UNIDO International Centre for Advancement of Manufacturing Technology (ICAMT), Bangalore on 25-26 Feb and 10-11 Mar 2014 (9.30am to 5.00pm). The students are pursuing Diploma in Mechanical Engineering with specialisation in Machine Tool Technology.

Turning Center Batch (25-26 Feb. 2014)

Class Room Session

In this session the participants learnt about:-

• Machine parts and its functions 1. Bed 2. Guide ways 3. Ball screw 4. Spindle 5. Tool turret 6. Tail stock 7. Steady rest

• Behaviour of CNC turning center

• Managing Spindle speed: -Calculating proper RPM in different operations and

different conditions.

• Managing Axes and its feed rates: - Specifying proper Feed rates and depth of cut in different operations and different conditions.

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• Process planning :- 1. Machining operations

(General turning, Grooving, Threading, Hole Machining) 2. Tooling

Material of the tool, ISO Inserts, ISO Holders and Selection of Tooling. 3. Cutting Parameter

Cutting speed, Feed rate, Depth of cut. 4. Work holding

3 Jaw, chuck 4 jaw chuck, Collet chuck, Soft Jaw, Hard Jaw. 5. Measuring Instruments

Vernier calliper, Micrometre, Bore dial gauge and plug gauges.

• Work Co-ordinates :-Mathematics for calculating co-ordinates by using rigonometry and Pythagoras

• Cycle Time calculation: - Cutting time, non-cutting time, tool changing time, spindle acceleration and deceleration time.

• G and M codes

• Part program: - Main program and sub program.

CAD CAM Practice

In this session participants learnt how to generate NC programs, Analysing Cycle time, Preparing process planning sheets and other shop floor related documents by using CAD CAM. They were taught how to utilise resources like CAD CAM to enhance the productivity and benefits like Speed, Accuracy, Safety, Skills and Standardization.

Hands on Session (Virtual Machine Software)

• Soft jaws boring technique • Setting cutting tools • Taking tool offset • Editing NC program • Editing tool data (Wear compensation) • Run the machine in single block

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• Edit the tool data after inspecting the first piece • Run the machine in Auto mode

List of Participants S. J. (Govt) Polytechnic, Bangalore

25 & 26 February 2014

SL NO NAME Phone No. 1 Mr. Abhishek kumar 8892494900

2 Mr. Abhishek C.L 9901764356

3 Mr. Adithya K S 8892140594

4 Mr. Amar Gowda C R 8861812470

5 Mr. Ananda S 8123315344

6 Ms. Asha S 9844815176

7 Mr. Athik-ur-rehaman 9036296098

8 Mr. Chandan Y V 97399878289

9 Mr. Chethan J R 7353461641

10 Mr. Devaraju S 9611672260

11 Ms. Divya R 8147039799

12 Mr. Fayaz Pasha 9741440093

13 Mr. Gururprasad 9738262443

14 Mr. Gururaj K K 9035509205

15 Mr. Harish kumar V 9035986919

16 Mr. Harsh S P 8553452265

17 Ms. Harshith Yadav T R 7259469040

18 Mr. Hemantha raj urs 9591670575

19 Mr. Kantha raj s K 9845573768

20 Mr. Karthik .V 9845286383

21 Mr. Kemparaju N C 9164552898

22 Mr. Kirankumar H 8867303896

23 Mr. Mahesh A 8867541262

24 Mr. Manjunath K N 9060759008

25 Mr. Manohara G S 9980467216

26 Ms. Neetha B S 8867100922

27 Mr. Rakshitha V 8553568081

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Machining Center Batch (10-11 March 2014)

Class Room Session

In this session the participants learnt about:-

• Machine parts and its functions Bed Guide ways Ball screw Spindle Automatic Tool Changer Automatic Work Changer

• Behaviour of CNC Machining center

• Managing Spindle speed: -Calculating proper RPM in different operations and

different conditions.

• Managing Axes and its feed rates: - Specifying proper Feed rates and depth of cut in different operations and different conditions.

• Process planning :-

Machining operations (Face Milling, Side Milling, Thread Milling, Drilling, Boring & Back Boring) Tooling (Material of the tool, ISO Inserts, ISO Holders and Selection of Tooling.) Cutting Parameter Cutting speed, Feed rate, Depth of cut. Work holding & Fixture.

• Work Co-ordinates :-Mathematics for calculating co-ordinates by using Trigonometry and Pythagoras

• G and M codes

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• Part program: -

Main program and sub program.

CAD CAM Practice

In this session participants learnt about generating NC programs, Analysing Cycle time, Preparing process planning sheets and other shop floor related documents by using CAD CAM. They were explained how to utilise resources like CAD CAM to enhance the productivity and benefits like Speed, Accuracy, Safety, Skills and Standardization.

Hands on Session

In this session participants learnt how to set the machine

• Aligning the work • Setting cutting tools • Taking tool offset • Editing NC program • Editing tool data (Wear compensation) • Run the machine in single block • Edit the tool data after inspecting the first piece • Run the machine in Auto mode

Benefits • Improved basic knowledge on machining technology and multi skill • Basic knowledge of ISO Inserts and Tool holders • Utilization of resources like CAD/CAM • Setting a goal for becoming a entrepreneur • Industry Ready Apprentices • Real practical exposure and feelings • Good programming practice

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List of Participants S J (Govt) Polytechnic, Bangalore

UNIDO-ICAMT CNC TRAINING BATCH for 10 & 11 Mar 2014

SL NO NAME Phone No. 1 Mr. Agasara Suresh Kumar 8722616124

2 Mr. Basavaraju K.M 9535430462

3 Mr. Javeed Pasha 7204669153

4 Mr. Mariswami 8197264987

5 Mr.Mithun B.S 9164663918

6 Mr. Mubarak Pasha 8867059817

7 Mr. Nagappa 8197245007

8 Mr. Nagaraj 8869136360

9 Mr. Nanjundaswamy 8971439079

10 Mr. Naveen K.S 8892629007

11 Mr. Nikhil .V -

12 Mr. Prajwal 776000690

13 Mr. Puneetha .R 7899887914

14 Mr. Ragavendra Kumar 8088881283

15 Mr. Santosh .C 9738014345

16 Mr. Shankarnag 9741220509

17 Mr. Shiva Vara Prasad .H.S 9880288561

18 Mr. Shivu.P.R 8892532478

19 Mr. Sudarshan 8722663131

20 Mr. Sujay Kumar .T 8050044884 21 Mr. Tahir Ali 9066532060 22 Mr. Trilochana.K.M 9738332281

23 Mr. Varun.V -

24 Mr. Veerappa 7411143357

25 Mr. Venkatesh M 9663321179

26 Mr. Vignesh.M 9449459599

27 Mr. Vinod.I 8553418872

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28 Mr. Lakshmi Kanth K.L 9164919470 29

Mr. Ramanujan.M 8553181759

30 Mr. Parthiban.R 9500334438

Feedback Analysis:

The training has helped the participants understand the importance of CNC Machining technology. This would help avoid any time wastage and would lead to efficient utilization of resources. It also gave them a thorough understanding of the steps involved in turning & milling programming.

A summary of the analysis of feedback provided by participants is shown in the table below.

Turning

Parameters Excellent Very Good Good Satisfactory Poor Training Programme content 100% 0%

Quality of Training 93% 7% Usefulness of this program to you 93% 7% Background Material (Hand out) 81% 19%

Milling

Parameters Excellent Very Good Good Satisfactory Poor Training Programme content 73% 27%

Quality of Training 50% 50% Usefulness of this program to you 88% 12% Background Material (Hand out) 62% 38%