A project report submitted in partial fulfilment of requirement

For the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

SUBMITTED BY

K . SIVA VENKATA SAI GANESH 17MU5A0305

Under the Guidance of

Mr. N. PRAKASH KUMAR M. Tech, M.B.A.,

Assistant professor

DEPARTMENT OF MECHANICAL ENGINEERING

SRI VENKATESWARA INSTITUTE OF SCIENCE AND

INFORMATION TECHNOLOGY

( Affiliated to JNTU-Kakinada, Approved by AICETE , New Delhi )

VENKATRAMANNAGUDAM

( 2016-2020)

DEPARTMRNT OF MECHANICAL ENGINEERING, VISIT COLLEGE

 SRI VENKATESWARA INSTITUTE OF SCIENCE AND
INFORMATION TECHNOLOGY
(Affiliated to JNTU, Kakinada, Approved by AICTE , New Delhi.)
Venkatramannagudem , Tadepalligudem , West Godavari Dist., A.p-534101

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that this project work entitled “ OPERATION MAINTENANCE AND
GROOVE CUTTING ON CNC ROLL TURINING LATHE MACHINE OF BILLET ”
that is being submitted by

K. SIVA VENKATA SAI GANESH 17MU5A0305

SRI VENKATESWARA INSTITUTE OF SCIENCE AND INFORMATION

TECHNOLOGY, Venkatramannagudem, Tadepalligudem in partial fulfilment of the
BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING is a bona-fide
work carried out by them under my guidance during the year 2019-2020.

PROJECT GUIDE HEAD OF THE DEPARTMENT

Mr. N. PRAKASH KUMAR, M. Tech., M.B.A., Dr. Md. AHASAN, Ph.D .,

Assistant Professor. Associate Professor.

EXTERNAL EXAMINER

DEPARTMRNT OF MECHANICAL ENGINEERING, VISIT COLLEGE

 ACKNOWLEDGMENTS

We extend our heart full gratitude to the almighty for giving us strength in
proceeding this project with respect and pride. We express sincere thanks to
SRI. CHERUKUWADA SRI RANGANATHA RAJU, Chairperson of our college for
making accessory arrangement for doing this project. We offer our profuse thanks to our
management.
We thank Dr. Md. AHASAN, Principal & HOD- Mechanical department for extending
his outmost support and cooperation in providing all the provision for the successful completion
of the project. With great solemnity and sincerity, we offer our profuse thanks to our
management.

We wish to express our sincere gratitude and indebtedness to the project guide
Mr. N. PRAKASH KUMAR., Assistant professor, Department of Mechanical Engineering for
creating interest in this field of project work, for his excellent guidance encouragement and
affection for the successful completion of this project work. His motivation encouraged us to
carry out this project work effectively.
We are grateful to Visakhapatnam steel plant for permitting and providing facilities to
carry out this project in ROLL SHOP & REAPAIR SHOP (RS&RS) department. We wish to
convey our humble regards to company guide MR .V.V.S.SRINIVAS (A.G.M of RS&RS ) his
esteemed guidance throughout the project period.

We thank all the teaching, non-teaching staff, friends and our Parents for their support in
executing this project. We finally thank all those who contributed directly and indirectly in
successfully carrying out this project work.

K. S.V. SAI GANESH 17MU5A0305

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE i

 DECLARATION

We hereby declare that the project work entitled “ OPERATION MAINTENANCE

AND GROOVE CUTTING ON CNC ROLL TURNING LATHE MACHINE OF BILLET ”
is the work done by us and submitted towards partial fulfilment of the requirements for the award
of the degree in “ Bachelor Of Technology In Mechanical Engineering ”, in Sri Venkateswara
Institute of Science And Information Technology, venkatramannagudem. And has not been
submitted to any other departments /university /institute for the any other degree.

BY

K.S.V.S.GANESH 17MU5A0305

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE ii

 LIST OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ACKNOWLEDGEMENTS i
DECLARATION ii
LIST OF CONTENTS iii - viii
LIST OF FIGURES ix - x
LIST OF TABLES xi
NOMENCLATURE xii
ABSTRACT xiii

1 INTRODUCTION 1
1.1 Raw material handling plant 2
1.1.1 Raw material send to departments 3
1.1.2 Wagon Tipplers 3
1.1.3 Stock Yards 4
1.1.4 Stacker 4
1.1.5 Reclaimer 5
1.1.6 Stacker cum Reclaimer 5
1.1.7 Screening and Crushing of Ore and coal 6

1.2 Coke ovens And coal chemical Plant 6

1.2.1 Department in CO&CPP 6
1.2.2 Process 6
1.2.3 Batteries 7
1.2.4 By Products 7

1.3 Coke Dry Cooling Plant (CDCP) 8

1.4 Coke Sorting Plant (CSP) 8

1.5 Sinter plant 9

1.5.1 Sinter 9
1.5.2 Sinter plant Consists of two sections 9
1.5.3 RMB ( Raw Material Bins) 9
1.5.4 Raw Materials From RMB 9
1.5.5 Raw Material From Coke Ovens 9
1.5.6 Process 10
1.5.7 Sintering the Material 10

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE iii

 1.6 Blast Furnace 11
1.6.1 Introduction 11
1.6.2 Hot Blast 12
1.6.3 Types of Blast Furnace 13
1.6.4 Blast Furnace-3 13
1.6.5 Modern process 13
1.6.6 Capacity 13

1.7 Steel Melting Shop 14

1.7.1 Introduction 14
1.7.2 CCM (Continuous Casting Machine) 14
1.7.3 Casting Process in CCM 15

1.8 Light Medium Merchant Mill 15

1.8.1 Introduction 15
1.8.2 Process 16

1.9 Medium merchant & structural mill 16

19.1 wire Rod Mill 17

2 LITERATURE REVIEW 18

3 Roll shop & Roll pass technology 20

3.1 Rolling mills and their classification 21
3.2 Roll Pass Design 23
3.3 Rolling Mills In VSP 25
3.3.1 End Products In Mills 25
3.3.2 Roll shop-1 25
3.3.3 Roll shop-2 25
3.3.4 Roll turning Shop 25
3.3.5 Major Equipment 25
3.3.6 Roll Turning Accuracies 25

3.4 Material & Specification 25

3.5 Design template for Rollers 26
3.6 Mechanism of Rolling 27
3.7 Roll pass Calculations For BH1 28
3.8 Roll Pass Calculations For modified BV3 29

4 Machining process 30
4.1 Single point cutting tool 31
4.2 Turning inserts Identification 33
4.3 Turning inserts used in project 37
4.4 Speed, Feed, Net power calculations 38
4.5 Cutting Fluids 41
4.5.1 Lubrication and cooling Action of Cutting Fluids 41
4.5.2 Requirements of A Cutting Fluid 41
4.5.3 Types of cutting Fluids 41
4.5.4 Application of Cutting Fluids 42

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE iv

 5 CNC Roll turning lathe machine 43
5.1 Bar mills 44
5.2 CNC lathe machine 45
5.2.1 Introduction 45
5.2.3 History of CNC 46
5.2.4 Numerical Control 46
5.2.5 NC Words 48
5.2.6 Machine Control Unit (MCU) 48
5.2.7 Machine Tool 48
5.2.8 CNC, MKNN, MJN NJJ parts 49

5.3 Classification of NC system 49

5.4 Machine control Unit (MCU) 50
5.5 Input Media For MCU 50
5.6 CNC Tooling 50
5.7 Advantages 50
5.8 CNC Working 51
5.9 Operation of CNC Lathe Machine 51
5.9.1 Introduction 51
5.9.2 Main Operation And Control Elements 51
5.9.3 Control Cabinet 52
5.9.3.1 Main Switch Drive 52
5.9.3.2 Main Switch Control 52
5.9.3.3 Voltage control of power supply 53
5.9.3.4 Current control of the power supply 53
5.9.3.5 Working Hour Meter 53
5.9.3.6 Emergency stop 53
5.10 Main Control Station At The Carriage 53

5.11 Operating Elements For Machine Control 53

5.11.1 Machine off 53
5.11.2 Machine-1 53
5.11.3 Hold all motions 53
5.11.4 NC-Man 53
5.11.5 Error 53
5.11.6 Diagnosis-Display 53
5.11.7 Data display unit 54
5.11.8 Fault Reset 54
5.12 Head Stock 54
5.12.1 Spindle speed 54
5.13 Tail stock 55
5.13.1 Adjustment of the centre shaft 55
5.13.2 Lubrication 55
5.13.3 Clamping of work piece between the centres 55
5.14 Turning Carriage 55
5.15 Service panel at the control cabinet 56
5.16 Service plane 56
5.17 Codes 56
5.17.1 G-codes 56
5.17.2 Motion Group 56
5.17.3 Dwell 56
DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE v
 5.17.4 Active plane Selection group 57
5.17.5 Cutter compensation Group 57
5.17.6 units group 57
5.17.7 Hole making Carried Cycle Group 57
5.17.8 Coordinate System Group 57
5.17.9 Pre-set 57

5.18 M- Codes 57
5.18.1 Group-1 57
5.18.2 Group-2 58
5.18.3 Group-3 58
5.18.4 Group-4 58
5.19 Precautions to be Taken in operation 58

5.20 CNC programming 59

5.20.1 Introduction 59
5.20.2 ` Cartesian Co-ordinate system 59
5.20.3 One Dimension 60
5.20.4 Two Dimension 60
5.20.5 Three Dimensions 61
5.20.6 Distance between two points 62
5.20.7 Programming system 62
5.20.8 Point to Point continuous path 64
5.20.9 Point to point Positioning 64
5.20.10 Continuous path contouring 65
5.20.11 Interpolation 66
5.20.12 Liner interpolation 66
5.20.13 Circular interpolation 66
5.20.14 Programming Format 67
5.20.15 Codes 67
5.20.16 Programming for Positioning 68
5.20.17 Dimensioning Guidelines 68
5.20.18 Work setting and offsets 68
5.20.19 Work Coordinates 70
5.21 Cutter Diameter Compensation 70
5.21.1 Advantages of CDC 70
5.22 CNC Program for -BH1 71
5.23 Work piece before Process 73
5.23.1 Work piece after Process 73

6 Mechanisms 74
6.1 Power drives 75
6.2 Rack and Pinion Mechanism 77
6.3 Ball screw mechanism 78
6.4 Worm and Worm Wheel Mechanism 78
6.5 Recent Advancements in CNC Machines 79
6.5.1 CNC cutting tool new product 79
6.5.2 Super Hard Material Field of CNC cutting tool 80
6.5.3 CNC cutting tool system 80
6.5.4 Applications 80

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE vi

 7 Maintenance 81
7.1 Preventive Maintenance 83
7.1.1 Check List for CNC Roll turning lathe monthly 84
7.1.2 Check List for CNC Roll turning lathe Quarterly 84
7.1.3 Maintenance Plane 85
7.1.4 Lubrication Instructions 86
7.1.5 Hydrostatic oil Tank 87

8 Estimation and costing 88

8.1 BH1 Roller manufacturing cost 89
8.2 Modified BV3 roller manufacturing cost 90

9 conclusion 92
9.1 References 93

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE vii

 LIST OF FIGURES

S. NO TITLE PAGE NO:

1.1 Raw material handling plant 2
1.2 Wagon tippler 3
1.3 Stock yard 4
1.4 Stacker 4
1.5 Reclaimer 5
1.6 Stacker cum Reclaimer 5
1.7 Batteries 7
1.8 Coke dry cooling plant 8
1.9 Sinter 9
1.10 Sinter machine 10
1.11 Blast Furnace 11
1.12 Blast furnace working 12
1.13 Steel melting shop 14
1.14 Continuous casting Machine 14
1.15 Casting process in CCM 15
1.16 Steel melting shop 16
1.17 Wire Rod Mill 17
3.1 7 stands of billet mill 23
3.2 Size reduction in billet 24
3.3 Template of BV3 Roller 26
3.4 Template of BH1 Roller 26
3.5 Mechanism of Rolling 27
4.1 Nose radius 32
4.2 Nomenclature of single point cutting tool 33
4.3 Insert shape & relief angle 34
4.4 Tolerance class 34
4.5 Chip breaker and clamping system 35
4.6 Insert size and thickness 35
4.7 Insert corner configuration 36
4.8 Chip cutting Direction 36
4.9 PSDNN cutting tool 37
4.10 PRSCL cutting tool 37
4.11 BH1 profile 38
4.12 BV3 profile 39
4.13 Discontinuous Chip 39
4.14 Continuous Chip 40
4.15 Sheared Chip 40
5.1 Bar in mill 44
5.2 CNC lathe machine 45
5.3 Components of NC system 46
5.4 Punched tape machine 47
5.5 Tape coding 47
5.6 Control Cabinet 52
5.7 Cartesian co-ordinate system 60
5.8 Two Dimensions system 61

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE viii

 5.9 Three Dimensions system 61
5.10 Programming system 62
5.11 Example for incremental system 63
5.12 Example for Absolute system 63
5.13 Point to point continuous path 64
5.14 Point to point positioning 64
5.15 continuous path contouring 65
5.16 Tool path 65
5.17 Liner interpolation 66
5.18 Circular interpolation 67
5.19 Work setting and offsets 69
5.20 Work setting movement 69
5.21 Work piece Before Process 73
5.22 Work Piece After process 73
6.1 Feed back system 75
6.2 Ac servomotor 76
6.3 Tail stock mechanism 77
6.4 Rack & Pinion Mechanism 77
6.5 Ball Screw Mechanism 78
6.6 Worm & Worm wheel mechanism 79
7.1 Types of maintenance 82
7.2 Graph of Preventive maintenance 83
7.3 Hydrostatic Oil Tank 87

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE ix

 LIST OF TABLES

TABLE NO TITLE PAGE NO:

1 Spindle speed table 54
2 Maintenance Plane 85
3 Lubrication instructions 86

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE x

 NOMENCLATURE NOMENCLATURE

Diameter of roller = D
Radius of roller = r
Width of the bloom before rolling = H0
Width of the bloom after rolling = H1
Reduction in rolling = ∆H
Angle of bite = α
Length = L
Pressure = p
Force = F
Arm factor = 𝛿
Torque = T
Angular velocity = 𝜔
Power = P
coefficient of friction = 𝜇
Angle = 𝜃
Depth of cut = ap
Feed = fn
Machine efficiency = ἠ
Cutting force = Kc
Cutting Speed = vc
Machining time = TC
Distance = D
Volume = V
Density = ῤ
Distance points = x, y

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE xi

 ABSTRACT
Computer numerical control (CNC) has been incorporated into a variety of New
technologies and machinery. One such machine of this sort that is used for a wide array of
production process is known as a CNC lathe. CNC lathes are replacing the old and more
traditionally used production lathes. The accuracy of CNC lathe machines are also high so in
this project we are used an CNC roll turning lathe machine.
In the steel bars or wire manufacturing process there are number of stages from the
raw material to final product, but the product final shape is given in the rolling mill. In the rolling
mill there are number of stands which are used to reduce the cross section of the billet from the
furnace. In the stands the steel is passed in between two rollers (Hot rolling) and the size reduction
in billet . As per the order from customer the rollers are changed to form different products. The
final products may be bars, wires, beams, sheets etc.

In our project we are replacing an old scrap roller from rolling mill and utilize in the
place of new roller to reduce the initial cost, maintenance cost, and working time of CNC turning
lathe in rolling mill of Vizag Steel Plant . by our project we save Investment cost to the RS&RS
department in Vizag Steel Plant.

DEPARTMENT OF MECHANICAL ENGINNERING, VISIT COLLEGE xii

.

CHAPTER : 1

DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 1

 INTRODUCTION
VSP has many different departments. Blast furnace produces huge amount of liquid metal
Continuously, this liquid metal is casted into blooms for further processing in SMS. SMS
Receives molten metal in ladles each with 150 tons of liquid metal through rail ways. The
out put of SMS is bloom of 250 x 250 cross section with a length of 6 m.
These blooms are sent to LMMM, WRM, MMM for further processing. the
Process starts from RMHP.

1.1 RAW MATERIAL HANDLING PLANT ( RMHP) :

VSP annually requires quality raw materials iron ore, fluxes, coking and non-Coking coals
etc, to tune 12-13 million tons for producing 3 million tons of liquid steel to handle
such a large volume of incoming raw materials received from different stores and to
ensure timely supply of consistent quality of feed materials to different departments . raw
material handling plant serves a vital function . This unit is provided with elaborate
unloading blending, stacking and reclaiming facilities .
The RMHP receives the basic raw materials required for steel
making process from various through rail way wagons. These are stacked by stackers and
reclaimed by reclaimers and distributed to various departments of VSP through conveyor
system. The iron ore fine, iron ore lump, sized iron ore, lime stone, sand, quartzite and
manganese lumps are stacked at ore and flux yard. The imported coking coal ,medium
coking coal and boiler coal is stacked at coal yard. Coke is directly sent to blast furnace
after tippling from ore and wagon tipplers.

Fig: 1.1 : Raw material handling plant

DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 2
 1.1.1Raw materials are send to various departments as shown below:

1. Sinter plant : Iron ore fines, lime stone (BF grade ),dolomite, sand and LD slag.
2. BF : sized iron ore, lime stone( BF graded)/LD slag, manganese lump, quartzite, coke .
3. SMS : Dolomite, sized iron ore, dolomite chips .
4. TPP : crushed boiler coal.
5. CO& CPP: Imported coking coal and medium coking coal.

1.1.2 Wagon Tipplers :

1. Wagon Tipplers are specially designed heavy electric machine which works on Rack
and pinion mechanism.
2. It tips the wagon with raw material up to and an angle of 180degrees to unload the raw
material.
3. VSP has 6 electric wagon tipplers and 1 hydraulic wagon tippler.
4. It works on rack and pinion mechanism.
5. when a wagon is tipped the
6. Before falling into the funnel the raw material passes through a screening mesh which
Lets the easy flow of the materials.
7. The funnel I s connected to conveyor belts which carries the raw materials to stackers.
8. All the conveyor belts are built under ground where they are able to change the flow
Of materials depending on the type and requirement.

Fig:1.2 : Wagon tippler

DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 3
 1.1.3 Stock Yards :
1. VSP has mainly two types of stack yard, ore stack yard and coal yard.
2. All the ore, raw materials, fluxes are stacked in ore stack yard.
3. Coking coal, boiler coal and pulverized coal is stacked in coal stack yard.

Fig:1.3: Stock yard

1.14 Stacker :
1. A Stacker is a large machine used in bulk material handling.
2. Its function is to pile bulk material such as coal on to a stockpile.
3. A Stacker can usually move in at least two directions : horizontally along the rail and
vertically by luffing ( Racing and Lowering ) its boom.
4. The conveyor belts used in stackers may be made of fabric or metal wire, depending
up on the material to be handled.

Fig:1.4 : Stacker
DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 4
 1.1.5 Reclaimer:
1. A re-claimer is a large machine used in bulk material handling applications.
2. A re-claimer function is to recover bulk material such as coal from a stockpile.
3. A re -claimer collets the coal through bucket attach to it and send to the conveyors .

Fig:1.5 : Reclaimer
1.1.6 Stacker cum Reclaimer:
1. The Stacker Reclaimers are used extensively in stockyards.
2. These are ideal for ensuring end-to-end logistics between incoming raw materials
and their processing in the plant .
3. They work as both stacker and reclaimer. It works in all directions.
4. Collection of material and loading both done with this machine.

Fig:1.6 : Stacker cum Reclaimer

DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 5
 1.1.7 Screening and Crushing of Ore and Coal :
1. In this the material is bought through conveyor belt and fed through a feeder and
passes through a screening mesh which is oscillating at an certain frequency of 5 hz.
2. After it gets crushed roller mechanism and then sent to particular department
through long conveyor system .

1.2 Coke Ovens And Coal Chemical Plant :

1. CO&CCP stands for Coke Oven & Coal chemical Plant.
2. The main purpose of CO&CPP is to convert coking into coke.
3. At present, VSP has 4 working batteries and one new battery under construction.
4. Coking coal after selective crushing and proper blending is subjected to destructive
distillation ( heating in the absence of air )in the coke oven.
5. The coke ovens of VSP are engineering feats by themselves, they are the tallest ovens
constructed in the country.
1.2.1Department In CO & CPP :
1. Batteries
2. CDCP
3. CSP
1.2.2 Process :
1. CO&CCP receives coking coal after selective crushing and proper blending from
RMHP through conveyor belts.
2. This coal is converted into coke in the coke ovens.
3. Coking coal is heated in the absence of air and in the presence of inert gases for
converting into coke.
4. The red hot coke from the ovens in dry-cooled in CDCP (Coke Dry Cooling Plant).
5. While dry-cooling the coke, the heat vented is collected and used in power production
through boilers.

6. After dry-cooling , the coke is sent to CSP ( Coke Sorting Plant).

7. In CSP , the coke is sorted into four different grades.

8. There are 2 CSP units where CSP-1 receives coke from CDCP-1&2, and CSP-2
receives coke from CDCP-3&4.

9. In CDCP after sorting of coal, the sorted coke is sent to the respective
Departments or plans for further utilization.

10. Main process in CSP are crushing and screening.

DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 6

 1.2.3 Batteries :
1. There are a total of 4 batteries in VSP.
2. Each battery has 68 heating walls and 67 ovens.
3. Each oven has a capacity of 32 tons coal.
4. Each oven is 7 meters in height and 16meters length.
5. Walls of oven are made of silicon bricks and are maintained at a temperature
Of 1000 degrees centigrade.
6. This coking coal is heated in the presence of CO gas and in the absence of air
for 18 hours.
` 7. After 18 hours the charging car pushes the coke to loco and transfer to CDCP
for Cooling and further process.
8. The coke is discharged into a loco wagon by a pusher car with the help of
pusher ram to the other side of the batteries.
9. Each loco has a capacity of 25 tons of coke.
10. These loco wagons are sent to CDCP ( coke dry cooling plant )for dry cooling.

Fig:1.7 : Batteries

1.2.4 By Products :

1. Ammonia
2. Sulphate
3. Thar
4. Napthalene ……etc.

DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 7

 1.3 COKE DRY COOLING PLANT ( CDCP ) :

1. Each CDCP has 4 cooling chambers where each chamber has capacity of 180 tons
of coke.
2. In CDCP red hot coke is brought by the loco wagon is charged in to cooling
chamber for dry cooling.
3. Cooling chamber are made up of silicone bricks.
4. Dry cooling takes 2 hours of time for one chamber with 180 tons of red hot coke.
5. After dry cooling the coke is collect from the cooling chamber and sent to CSP
( coke sorting plant ) drought conveyor belt.

Fig:1.8 : Coke dry cooling plant

1.4 COKE SORTING PLANT ( CSP) :

1. VSP has 2 CSP units, where CSPI process the coke from CDCP 1&2 and CSP2
from CDCP 3&4.
2. The main purpose of CSP is to sort the dry cooled coke from CDCP in 3 grades by
its size and crushing of coke and then convey them to other departments for further
utilization.
3. The processes in CSP are crushing and screening.
4. In CSP coke is first crushed by the rollers of 70 mm.
5. Then the coke is send through 3 screening processes for grading into 3 different sizes.
6. Coke between 70 to 20 mm is sent to blast furnace
7. Coke between 20 to 10 mm is called as nut coke which is sent to sinter plant.
8. Coke below 10 mm is called as breeze coke which is sent out for commercial purpose.
DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 8
 1.5 Sinter Plant :

1.5.1 Sinter : It is an odd , porous , ferrous material it is to be obtained .

Fig:1.9 : Sinter

1.5.2 Sinter plant Consists Of Two Sections :

1. RMB : Raw material bins.

2. SMB : Sinter machine building.

1.5.3 RMB[Raw Material bins] :

In This RMB, the materials are taken from RMHP & coke ovens.

1.5.4 Raw Materials From RMB:

1. Limestone
2. Quartz
3. Dolomite

1.5.5 Raw Material From Coke Ovens :

1. Coke

DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 9

 1.5.6 Process :
1. From the store yard, the coking coal is sent to foreign material removing section
to remove foreign matter of about 150 mm size.

2. Iron traps for ferromagnetic articles and cylindrical screens provided for this.

3. 16 number of bins each 800 tonnes capacity are provided along with Continuous
action feeders of up to 100 tonnes per hour capacity each.

4. After blending the material is crushed to take care of petrographic Non-uniformity,

high hardness and mineral content of crushed and blended coal
( 74-78% of 3 mm size is conveyed to two coal towers each of 4000 ton capacity).

5. Weighbridge are provided under coal towers to weight the coal charge.

6. System of pneumatic blow down of blend is provided in the coal tower

to take care of jamming of coal.

1.5.7 Sintering The Material :

1. Material is put on a sinter machine in two layers. The bottom layer may vary
in Thickness from 30 to 75 milli meters ( 1.2 to 3.0 in ) .

2. A 12 to 20 mm sinter fraction is used, also referred to as the hearth layer.

3. The second , covering layer consists of mixed materials, making for a total bed
height of 350 to 660 milli meters ( 14 to 26 in).

4. The mixed material are applied with drum feeder and roll feeders, which
distribute the nodules in certain depth through the sintering machine.

5. The upper layer is smooth using a leveller the material, also known as charge ,
enters the ignition furnace into rows of multi-slit burners . In the case of one plant,
the first ( ignition )zone has eleven burners.

6. The next ( soaking/annealing ) zone typically offers 12 burner

Fig:1.10: Sinter machine

DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 10
 1.6 BLAST FURNACE:

1.6.1 Introduction :

1. A blast furnace is a type of metallurgical furnace used for melting to produce

Industrial metals , generally pig iron, but also other such as lead or copper .
Blast refers to the combustion air being “ forced ” or supplied above atmosphere
pressure .

2. In a blast furnace, fuel, coke, ores, and limestone are continuously supplied
through the top of the furnace, while a hot blast of air is blown into the lower
section of the furnace through a series of pipes so that the chemical reaction
take place through the furnace as the material falls downward.

3. The purpose of blast furnace is to reduce and convert iron oxides into liquid
iron which is called as “ hot metal ” .

4. The blast furnace is a huge steel stack lined with refractory brick.

5. The iron ore , coke and limestone are dumped into the top and preheated
air is blow into the bottom .

Fig:1.11 : Blast Furnace

DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 11
 1.6.2 Hot Blast :

1. Hot blast was developed by one third using coke or two third using coal, while furnace
capacity was also significantly increased.

2. It consists of a stove as large as the furnace next to it into which then waste gas which
contain co from the furnace was directed and burnet.

3. The resultant heat was used to preheat the air blown to the furnace.

4. The stove is a vertical cylindrical steel shell lined with firebrick and with interior separated
into two chambers : a combustion chamber in Which gases from blast furnace and other
fuel source such as coking plant are burned, and a regenerative chamber.

5. The blast furnace consists of three stoves; while two are being heated the air
Blast passes through the third stove ; while two are being heated.

6. The blast furnace fed with air that has been preheated to temperature from 900
to 1,250 0C
7. It can generate melting temperature of about 1,650 0C .

Fig:1.12 : Blast furnace working

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 1.6.3 TYPES OF BLAST FURNACE :

1. There are three types of blast furnaces.

2. Two blast furnaces of 3200 cum useful volume each.
3. One blast furnace of 3800 cum useful volume ( BF-1 & BF-2)
4. Conveying charging of blast furnaces.
5. Paul-worth “Bell less” top charging system for blast furnace.
6. Circular cast house with 4 tap holes and no slag notch.
7. Cast house slag granulation plant,
8. Automation with programable logic controllers.
9. On-line correction of coke moisture and batch weights.

1.6.4 Blast Furnace-3 :

1. New generation parallel hopper bell less top.

2. BF cooling elements [ Cast iron 2 copper stoves .
3. Flat cast house equipment [ by tmt].
4. INBA slag granulation system.
5. Pulverized coal injection system.
6. Hot stoves.
1.6.5 Modern process :

1. The raw materials are transferred to the stock house complex by ore bridges .
2. The raw material are brought to the top of the blast furnace with the help of conveyor
belts. There are different ways in which the raw materials are charged into the blast
furnace.
3. Some blast furnace use a double bell system where two belts are use to control the
entry of raw material into the blast furnace.
4. The purpose of the two belts is to minimize the loss of hot gages in the blast furnace
First the raw materials are emptied into the upper or small bell which then open to employ
the charge into the large bell.
5. The small bell then closes, to seal the blast furnace, while the large bell rotates to provide
specific distribution of materials before dispensing the charge into the blast furnace.

1.6.6 Capacity :
1. Production capacity 3.4 MT of hot metal per annum for blast furnace 1&2
2. Production capacity 2.5 MT of hot metal per annum for blast furnace 3
3. Visakhapatnam steel plant has two blast furnace with an effective volume of 3200m3 .
Each of which are the largest in the country.
4. Blast furnace is charged with coke, iron ore, and sinter from the top and produces about
5000 tons of molten iron per day.
5. Their novel circular cast house with four tap hole ensures continuous tapping of hot metal.
6. The annual production capacity of these blast furnace is 3.4 million tons of liquid iron.
7. Iron is produced in the blast furnace with the help of coke and air.
8. The solid charge materials like sinter, sized iron ore, coke charged in the vertical shaft of
the blast furnace from top and hot air blast is blown through tuyeres located at the bottom.
9. The oxygen present in hot air combines with the carbon of coke and generates heat and
carbon monoxide ( reducing agent ).
10. Eventually the charge gets reduced and hot metal, slag and BF gas are produced. Hot metal
and slag is tapped from tap hole.

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 1.7 Steel Melting Shop
1.7.1 Introduction :

1. Blast furnace produces huge amount of liquid metal continuously, this liquid metal is casted
into blooms for further processing in SMS.
2. SMS receives molten metal in ladles each with 150 tons of liquid metal through rail ways.
3. SMS has a total of 4 radial type continuous casing machines (CCM).
4. The output of SMS is blooms of 250 x 250 cross section with a length of 6m.
5. These blooms are sent to LMMM, WRM, MMM for further processing

Fig:1.13 : Steel melting shop

1.7.2 CCM (Continuous Casting Machine ):

1. CCM is a specially designed machine which casts molten metal continuously.

2. It mainly consists of ladle, ladle turret , reservoir, mould oscillator , casting mould,
cooling zones guide rods and gas cutter.
3. In casting machine ladle has 150 tons of liquid metal and has a casting time of one hour.

Fig:1.14 : Continuous casting Machine

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 1.7.3 Casting Process in CCM :

1. At first the ladles which comes with liquid metal on rail way are lifted with a crane and
placed in open hand of ladle turren. Ladle turren is a electric machine which holds and
rotated the ladle towards the reservoir. Each ladle has sub entry nozzle at bottom to let the
molten metal out into the reservoir at a constant flow.
2. Each CCM has 6 casting outlets, when the liquid metal falls into reservoir the metal goes
into 6 different moulds. The reservoir is attached with a mould oscillator which allows the
free flow of metal through the mould.
3. CCM has 4 cooling zones. The first cooling zone is present inside the mould which is a
spray cooling which cools the outer surface of the bloom and increases the strength of the
bloom. Then acts the second cooling zone which is also a spray cooling at the end of the
mould , it cools the inner metal of the bloom and allows the bloom to completely solidify.
and then the casted bloom passes through the guide rods, which initially sets a path to the
continuous square metal coming out of the mould. Then a gas cutter cuts the casted metal
into 6m length blooms.
4. Then acts cooling zones 3 and 4 which cool down the bloom further.
5. Then the blooms are lifted on to conveyor rolls with the help of LLTC which is an electric
machine and works on pulley mechanism.

Fig:1.15 : Casting process in CCM

1.8 LIGHT MEDIUM MERCHANT MILL

1.8.1 Introduction:

LMMM comprises of 2 units. In the billet (or) breakdown mill (250x320 mm) size blooms
are rolled into billets of (125x125mm) size after heating them in any one of the 2 walking beam
furnaces of 200 tons/hour capacity each. The unit comprises of 7 stands 2 horizontal and 5
alternating vertical & horizontal stands (730x1000m.m &630x1000m.m) and in middle they are
passed through roller heave furnace which maintains the temperature in the blooms. Billets are
supplied from this mill to bar mill& wire rod mill.

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 1.8.2 Process:

1. From, SMS the blooms will come to the LMMM store yard, which is at a size of 250x250mm
and then these blooms are charged to the furnace.
2. It is a PNUMEATIC mechanism.
3. Those blooms are charged in the furnace for 72 hours under 5 zones.
4. In those there are 3 re-heating zones and 2-soaking zones.
5. In 1200 c blooms are heated and then there are discharged.
6. The blooms are sent into roller and then there are compressed. And then each bloom is
divided into 3 billets.
7. In these 2 billets are sent into WRM&1 billet is sent into LMMM. And these billets are
heated in re-heating furnace.
8. After coming out of rollers, billets are compressed and it is extended the final product is
obtained.
9. INPUT: BLOOMS.
10. OUTPUT: RODS.

Fig:1.16 : Steel melting shop

1.9 Medium merchant & structural mill
Medium merchant and structural mill is a high capacity continuous mill consisting
stands arranged in 3 trains as detailed below.
1. Roughing train having 8 stands.
2. Intermediate train has 6 mill stands as per details given below.
3. 2 high horizontal stands.
4. 2 combination stands.
5. 2 horizontal stands/ two universal stands finishing train- consists of 6 stands namely.
6. 2 combination stands.
7. 4 horizontal stands/4 universal stands.
The feed material to the mill is 250x250 mm size blooms, which is heated to a rolling
temperatures of 12000c in two walking beam furnaces. The mill is designed to produce
8,50,000 tons per annum of various products such as
1. Rounds
2. Squares
3. Flats
4. Angles (equal and unequal)
5. T bars
6. Channels
7. IPE beams( universal beams)
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 19.1 WIRE ROD MILL
Introduction:
Wire rod mill is 4 strands, 25 stands fully automated and sophisticated mill. The mill has
four zone combination type reheating furnace of 200TPH capacity for the billets received from billet
mill of LMMM to rolling temperature12000c.

The heated billets are rolled in 4 stands no twist continuous mill having a capacity of
850000 tonnes of wire rod coil and having the following configuration.

1. 7 stand two high 4 stand horizontal roughing train.

2. 6 stand two high 4 stand horizontal intermediate mills.
3. 2 stand 4 stand pre-finishing mill.
4. 10 stand 4 stand no twist finishing mill.

The mill produce rounds in 5.5-12 mm range and re-bars in 8-12mm range. The
mill is equipped with standard and retarded strand lines for producing high quality wire rod in low
medium strand lines for producing high quality rods in low, medium and high carbon grade meeting
the stringent nation and international standards viz. and having high ductility grain size excellent
surface finish.

Fig:1.17 : Wire Rod Mill

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 CHAPTER: 2

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 LITERATURE REVIEW
• A lathe is one of the oldest and most important machine tools ever developed. The
job to be machined by rotating and the cutting tool moves related to the job. The
lathes are developed to machine cylindrical surfaces. The CNC lathe machine is one of the
best advancement in the lathe machines. The working on CNC lathe is very easy as
compared to the traditional lathe machine. The operating time and machining process is very
accurate . International Journal of Advanced Scientific Research ISSN:2456-0421
www.newresearchjournal.com/scientific Volume 1; Issue 1; April 2016; Page No. 13-17.
A research on Cutting Forces in Turning Operations, Sergi Martín Umbert ,Mechanical
engineer , Norwegain University of Science and Technology, Journal is used to calculate the
cutting forces and tool wear are taken from this jornal. CNC Machine Maintenance
Scheduling with Reliability Engineering Method and Maintenance Value Stream Mapping,
N Sembiring and A H Nasution Departemen Teknik Industri, Fakultas Teknik, Universitas
Sumatera Utara, Jalan Almamater Kampus, Medan 20155.

• The rollers are used in the billet mill to reduce the cross section of the hot billet
coming from the furnace. The roller plays major role in the billet mill. Computer-aided roll
pass design for continuous billet mill ASHOK KUMAR, SUDHAKER JHA and V
RAMASWAMY Research & Development centre for Iron and Steel, Journal is for the
Reference to CNC operations and programming process .
Dr. P.C Sharma Production Technology book is used for the Theory of Roll pass, Roll pass
design and angle of bite calculations.
R.S KURMI. Machine Design book is used to the design calculations of roller, load
calculations, design considerations.

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 CHAPTER: 3

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 RS&RS DEPARTMENT
Rolling shop is effected in rolling mill stand by passing the material between the
grooves in the top and bottom rolls. The passes tend to wear out in service and gradually lose
their initial shape resulting in the size , surface finish of the product being rolled deviate from the
allowable tolerances. This is remedied of pass are restored of its original dimensions. This
process is called re dressing.

3.1 ROLLING MILLS AND THEIR CLASSIFICATION:

A rolling mill is a complex of machines for deforming metal in rotary rolls and performing
auxiliary operations such as transportation of stock to rolls, disposal after rolling, cutting,
cooling, melting, piling or coiling etc. A set of rolls in the massive housing is called a “stand”.
Rolling mills are classified according to the number of rolls in the working stand, the product
rolled, arrangement of stands etc.

1. Classification based on number of rolls in the stand:

According to this criteria, rolling mills are of the following types:
a) Two high rolling mill:
As the name implies, it has two rolls with a constant direction of rotation about the
horizontal axes. For successive reductions, the stock is returned to the entrance of the rolls by
hand carrying or by means of a platform which can be raised to pass the stock over the
rolls.The upper roll may be raised or lowered to change the distance between the rolls. This
method of successive reductions slows down the process. The faster method is to pass the
stock through a series of rolls for successive reduction, but this method requires more
investment in equipment. The alternative procedure is to use “tow high reversing” rolling
mill, where the direction of rotation of the rolls is reverse after each pass. The rolls are
brought closer together after each pass and the bar or plate reciprocates many times between
the rolls before the final thickness is obtained. This design is limited by the length that can
be rolled and by the inertial forces that must be overcome each time a reversal is made.

b) Three high rolling mill:

The disadvantages of a two high reversing mill are overcome by using a three-high
rolling mill in which three rolls with a constant direction of rotation are arranged in a single
vertical plane. Lifting tables are provided on one or both sides of the stand to rise and lower
the bar after each pass. In these mills, the top and bottom rolls are drive rolls and the middle
roll rotates by friction.

c) Four-high rolling mill:

For a given width plate/sheet and reduction per pass, the bending of the rolls will be
less as their diameter is increased. However, increasing the roll diameter will increase the arc
of contact between the roll and the plate/sheet. This will result in an increase in roll
separating force.

d) Multiple-roll mill:
In four-high rolling mill, the diameter of back up rolls cannot be greater than 2 to 3
times that of the work rolls. As the diameter of work rolls is decreased more and more to
accommodate processes with exceedingly high rolling loads, the size of the backup rolls must
also decrease. A point is reached when the backup rolls themselves begin to bend and must be
supported, hence the ultimate-design-cluster mill.

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 e) Universal rolling mill:
In this rolling mill, the metal is reduced by both horizontal and vertical rolls. The vertical
rolls roll the edges of the bar even and smooth. Vertical rolls are mounted either on one side
(front or back) or on both sides of the horizontal roll stand. The horizontal rolls may be either
two, three, or four-high arrangement. These mills are used for rolling wide strip, sheets, plates
and slabs that require rolled edges and also for rolling of beams and H-sections.
2. Classification based on the products rolled:
According to the products rolled, the rolling mills may be classified as follows:
a) Blooming and slabbing mills:
These are heavy mills with rolls from 800 to 1400 mm in diameter. They are designed to
roll ingots into blooms and slabs. Since blooming mills and slabbing mills are quite
similar, these are called as primary mills.
b) Billet mills:
These mills have rolls 450 to 850 mm in diameter and are designed to further reduce
blooms into billets.
c) Rail and structural mills:
These mills have rolls from 750 to 800 mm in diameter and are used mainly to produce
railroad rails, beams, channels and other heavy structural shapes.
d) Section mills:
Have rolls from 250 - 750 mm in diameter, depending upon shape and section to be rolled.
e) Rod mills:
Have rolls about 250 mm in diameter and are used to produce wire rod.
f) Sheet and plate mills:
Have barrel lengths ranging from 800 to 5000 mm for hot rolling and from 300 to 2800
mm for cold rolling.
g) Seamless tube mills:
Produce seamless tubes as discussed later.
h) Tyre and wheel mills:
Are used to manufacture rail-road wheels and tyres.

3. Arrangement of rolling stands:

Single stand mills are used singly or in various floor layout combinations for rolling metals.
a) Looping mill:
The products are looped from one mill stand to another by arranging the stands in a
”train” in which the rolls of one mill stand are driven from the ends of the rolls in the
adjacent stand.
b) Cross-country mill:
It consists of individual roll stands placed some distance apart so that the work piece
must leave one set of rolls before it enters the next set. To save space and avoid
complicating the mill drive mechanism, the roll stands are generally arranged in one or
more parallel lines. Transfer and skid tables are used to reverse the direction of travel of the
work piece and to convey it from set of roll stands to another.

c) Continuous mill:
It employs a number of individual roll stands arranged one behind the other in a straight line
(in tandem). The work pieces continuously pass through the various roll stands and emerge
from the last roll stand as a finished shape. The rolls of each successive stand must turn
faster than those of the preceding one by a precise amount so as to accommodate the
increased length which accompanies each successive reduction in thickness.
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 3.2 ROLL PASS DESIGN:
As already discussed, because of the limitations in the equipment and work ability of
the metal, rolling is accomplished progressively in many steps. Plate, sheet and strip are
rolled between rolls having a smooth, cylindrical, slightly cambered (convex) or concave
working surface. Bars, rods and special purpose shapes (I-beams, channels and rails etc.) are
rolled between grooved rolls. The shape cut into one roll is called the “groove”. The shape
formed when the grooves of the mating rolls are matched together is called the “pass”. By
rolling the metal consecutively through the passes, the initial square or rectangular cross-
section of the ingot (bloom or billet) can be gradually changed to obtain a bar of the final
required shape.
Accordingly to their designation, passes fall into the following groups:
a) Break down passes:
These passes are intended to reduce the cross-sectional areas.
These passes may be of the: rectangular (box), diamond square and oval shapes,

i) Box passes:
These passes are employed in blooming mills, and in roughing and continuous billet
mills. The reduction varies from 10% to 30% and the co-efficient of elongation from 1.1
to 1.25. The stock is titled through 90º after each pass.

ii) Diamond passes:

Diamonds with obtuse angles from 90º to 100º are commonly employed. The co-efficient
of elongation will be 1.2 to 1.4.

iii) Diamond-square series:

In which diamonds alternate with squares is used chiefly in rolling square bars and
flats. Diamonds with obtuse angles from 100º to 125º are employed in this series. The co-
efficient of elongation ranges from 1.25 to 1.50. The short coming of the series is deep
passes which weaken the rolls.
iv) Oval-square series:
This is the most effective and wide-spread series. Its chief advantage is larger
co-efficient of elongation (1.5 to 2.5 or even higher). Larger elongations enable very
small sections to be rolled and, therefore, this series is the main sequence used in
producing wire-rod and other small sections.

• In the rolling mill the following series of passes are given to the billet
• The billet input size is 320 × 250 mm, out put size 125× 125 mm billet
• There are total 7 stands in the billet mill, then the billet is send to the wire rod
mill

Fig:3.1 7 stands of billet mill

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 The 7 stands size reduction is shown in fig , there are total 7 stands . In the 7 stands 4
stands are horizontal rolling and 3 stands are vertical rolling. To reduce the billet size.

Fig :3.2: Size reduction in billet

b) Leader passes: The function of these passes is to gradually bring the cross section of the bar
to the final shape. The finishing pass for rolling rounds is preceded by an oval leader pass, the
finishing pass for rolling squares is preceded by a diamond leader pass etc.

Two decentralized roll shops are envisaged in the VSP for catering to the needs of
3 rolling mills.
1. Rolling mills in VSP.
2. End products in mills.
3. Roll turning shop.
4. Major equipment.
5. Roll turning accuracy.
6. Materials and specifications.
7. Roll shop-1
8. Roll shop-2

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 3.3 ROLLING MILLS IN VSP:
In VSP the rolling takes places in 3 rolling mills, these are
1. Wire rod mill
2. Light medium merchant mill
3. Medium merchant structural mill.

3.3.1END PRODUCTS IN MILLS:

1. In WRM the end products are wires.
2. In LMMM the end products are billets, bars, rounds.
3. In MMSM the end products are rounds, angles, channels, beams, flats.
4. VSP contains two roll shops
• ROLL SHOP-1 supplies roller’s to LMMM AND WRM.
• ROLL SHOP-2 supplies roller’s to MMSM.

3.3.2ROLL SHOP-1:
It comprise of a roll turning shop, bearing shop a specialized repair shop and roll storage area.

3.3.3 ROLL SHOP-2:

This roll shop also contains 6 WASI roll turning shop and bearing shop a specialized repair
Shop and roll storage area.
3.3.4 ROLL TURNING SHOP:
The basic function is to initially turns the grooves on a roll barred as per the groove
drawing and distribution schemes, accordingly to rolling program of the mills . Therefore re-
dressing of these rolls at frequent intervals depending upon their usage and service in the mill
is done. The estimated work load on this about 1400 new and 5500 used roll per year.

3.3.5 MAJOR EQUIPMENT:

1. CNC rolls turning lathes 6
2. CNC notch milling machine-1
3. CNC template milling machine-1

3.3.6 ROLL TURNING ACCURACIES:

1. True running ---0.02 mm
2. Cylinder city ---0.00/300 mm
3. Deviation from profile ---0.02mm through L80
4. Surface finish (peak valley hight)-6u

3.4 MATERIALS & SPECIFICATION:

Alloy forged steel, alloy cast steel, Nodular cast iron, doubled purred Cast iron of varying
hardness from 40 to 77 . The roll shop contains 6 WASI roll turning machines.

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 3.5 DESIGN TEMPLATE FOR ROLLERS:
TEMPLATE OF BV3 ROLLER:

Fig:3.3 : Template of BV3 Roller

TEAMPLATE OF BH1 ROLLER:

Fig:3.4 : Template of BH1 Roller

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 3.6 MECHANISM OF ROLLING:
The metal contacts each of the two rolls along the arc AB, which is known as the
arc of contact. This arc corresponds to the central angle α, called the “angle of contact of
bite”. The process of metal rolling is made possible by the friction that occurs between the
contact surfaces of the rolls and the part being rolled. At the moment of bite, two forces
act on the metal from the side of each roll, normal force P and the tangential force µP
where µ is the co-efficient of friction of friction between the metal and the roll surfaces.
The part would be dragged in if the resultant of horizontal component of the normal force P
and tangential force (frictional force) µP is directed in that direction. In the limiting case,
𝑃 𝑠𝑖𝑛 𝛼 = µ 𝑃 𝑐𝑜𝑠 𝛼
µ = 𝑡𝑎𝑛 𝛼
or
𝛼 = 𝑡𝑎𝑛−1 𝜇

Fig:3.5 :Mechanism of Rolling

If α is greater than 𝑡𝑎𝑛−1 𝜇, the metal would not enter the space between the rolls
automatically, that is, unaided.

The maximum permissible angle of bite depends upon the valve of ‘µ’ which in turn depends
upon the materials of the rolls and the job being rolled, the roughness of their surfaces, and the
rolling temperature and speed.
In hot rolling, the primary purpose is to reduce the section and hence the maximum possible
reduction is desired. So, the value of α and hence of µ should be greater. In hot rolling, lubrication
is generally not necessary. On the other hand, on primary reduction rolling mills such as blooming
or rough rolling mills for structural elements, the rolls may sometimes be “ragged” to increase µ.
Ragging is the process of making certain fine grooves on the surface of the roll to increase the
friction. In cold rolling, the rolling loads are very high, hence should not be much. Besides, cold
rolling being a finishing operation, rough rolls will impair the surface of the cold rolled product.
Due to this, rolls for cold rolling are ground and lubricants are also used to reduce µ.

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 3.7 ROLL PASS CALCULATIONS FOR BH1 :
Diameter of the roller (d) = Ø850 mm
Radius of the roller (R) = 425mm
Width of bloom before rolling (H0) = 320 mm
Width of bloom after rolling (H1) = 275 mm
Width reduction in rolling(ΔH)= H0-H1 = (320-275) = 45 mm

∆𝐻 45
𝑅− 425−
Angle of bite (α) = cos−1 ( )
2
=cos −1 ( )
2
= 19֯
𝑅 425

∆𝐻 45
Maximum reduction conditio = tan 𝛼(𝜇) =√ 𝑅 = (√425 ) = 0.1028
General Neutral plane(Hn)= H1 +(20-30%) ∆𝐻 = 275+(0.2)45 = 284 mm

Hn 284
Back ward slip = ( 1-H0 ) = (1-320 ) = 0.1125 = 11.25%
Hn 320
For ward slip = ( H1 -1) = (275 − 1) = 0.1636 = 16.36%

Deformation length (L) = √𝑅 × ∆𝐻 = √425(45) = 138.29 mm

2𝜇𝐿 2× 0.1028 ×√45×425
n = = = 0.63
∆𝐻 45
𝐻0+𝐻1 320+275
H = = = 297.5 mm
2 2

𝜎 H0
Maximum pressure at neutral axis (plag) = [𝑛 (n-1) [Hn]n +1]
250 320
= [0.63 (0.63 − 1) [284] 0.63 + 1]

= 23.85 𝐾𝑔⁄𝑐𝑚2

2 𝜇𝐿
Average pressure (pavg) = 𝜎(1 + 4𝐻)
√3
2 0.1028×138.29
= (250)(1 + )
√3 4×297.5
2
= 409 𝐾𝑔 𝑐𝑚 ⁄
Arm factor (𝛿) = 0.3-0.4

Average pressure
Average force on roller(FAvg) = ×Projected area
2
409
= ×275× 138.293
2
= 11109491.56 N

Torque (T) = Favg × 𝛿 ×L

= 111109491.56×0.3×138.29
= 460909474.89 N-mm
= 460909.47 N-m

2𝜋𝑁 2𝜋(10)
Angular Velocity (𝜔) = = =1.047
60 60
Power (P) = 2× 𝑇𝑜𝑟𝑞𝑢𝑒 × 𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦(𝜔)
= 2 × 460909.47 ×1.047
=965144.43 W =965.32 kw

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 3.8 ROLL PASS CALCULATIONS FOR MODIFIED BV3 :
Diameter of the roller (d) = Ø730 mm
Radius of the roller (R) = 365mm
Width of bloom before rolling (H0) = 320 mm
Width of bloom after rolling (H1) = 275 mm
Width reduction in rolling(ΔH)= H0-H1 = (320-275) = 45 mm

∆𝐻 45
𝑅− 365−
−1 −1
Angle of bite (α) = cos ( 2
) =cos ( 2
) = 21֯
𝑅 365

∆𝐻 45
Maximum reduction conditio = tan 𝛼(𝜇) =√ 𝑅 = (√365 ) = 0.351
General Neutral plane(Hn)= H1 +(20-30%) ∆𝐻 = 275+(0.2)45 = 284 mm

Hn 284
Back ward slip = ( 1-H0 ) = (1-320 ) = 0.1125 = 11.25%
Hn 320
For ward slip = ( H1 -1) = (275 − 1) = 0.1636 = 16.36%
Deformation length (L) = √𝑅 × ∆𝐻 = √365(45) = 128.16 mm
2𝜇𝐿 2× 0.351 ×√45×365
n = = = 1.999
∆𝐻 45
𝐻0+𝐻1 320+275
H = = = 297.5 mm
2 2

𝜎 H0
Maximum pressure at neutral axis (plag) = [𝑛 (n-1) [Hn]n +1]
250 320
= [ (2 − 1) [ ] 2 + 1]
2 284

= 28 𝐾𝑔⁄𝑐𝑚2

2 𝜇𝐿
Average pressure (pavg) = 𝜎(1 + 4𝐻)
√3
2 0.351×128.16
= (250)(1 + 4×297.5 )
√3
= 300 𝐾𝑔 𝑐𝑚⁄ 2
Arm factor (𝛿) = 0.3-0.4
Average pressure
Average force on roller(FAvg) = 2
×Projected area
300
= 2
×275× 128.16
= 10573200 N
Torque (T) = Favg × 𝛿 ×L
= 10573200×0.3×128.16
= 406518393.6 N-mm
= 406518.39 N-m
2𝜋𝑁 2𝜋(10)
Angular Velocity (𝜔) = = =1.047
60 60
Power (P) = 2× 𝑇𝑜𝑟𝑞𝑢𝑒 × 𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦(𝜔)
= 2 × 406518.39 ×1.047
=851249.50 W = 851.24 kw

• The angle of bite increases the reduction in the thickness of the strip increases.
• Maximum bite angle (𝛂) is less than or equal to the angle of friction.
BH1 roller angle of bite(𝛂) = 19°
Modified BV3 angle of bite(𝛂)= 21°

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 CHAPTER:4

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 MACHINING PROCESS
4.1 Single point cutting tool :
A single point cutting tool consists of a sharped cutting part called its point and the
shank. The point of the tool is bounded by the face , the side flank or major flank the end flank.
The chips are cut from the work piece by the side-cutting edge. The point ‘a’ where the end
and side-cutting edges meet is called the ‘nose’ of the tool. The fig shows right hand tool.

Shank: It is the main body of the tool.

Flank: The surface or surfaces below and adjacent to the cutting edge is called flank of the tool.
Face: The surface on which the chip slides is called the face of the tool.
Heel: It is the intersection of the flank and the base of the tool.
Nose: It is the point where the side cutting edge and end cutting edge intersect.
Cutting edge: It is the edge on the face of the tool which removes the material from the
workpiece. The total cutting edge consists of side cutting edge, end cutting edge .The single
point cutting tool are either right or left hand cut tool depending on the direction of feed given.
The references from which the tool angle are specified are the ‘cutting plane’ and the ‘basic
plane’ or the ‘principal plane’. The cutting plane is the plane tangent to the cutting surface and
passing through and containing the side cutting edge. The basic plane is the plane parallel to the
longitudinal and cross feeds, that plane lies along and normal to the longitudinal axis of the work
piece.
Side cutting-edge angle Cs: It is the angle which prevents interference as the tool enters
the work material. The tip tool is protected at the start of the cut, shown in figure as it enables
the tool to contact the work first behind the tip. The angle affects tool life and surface finish.
This angle can vary from 00 to 900. The side cutting edge at increased value of SCEA will
have more of its length in action for a given depth of cut and the edge lasts longer. Also, the
chip produced will be thinner and wider will distribute the cutting and heat produced over
more of the cutting edge. On the other hand, component of force tending to separate the work
and the tool. This promotes chatter. Satisfactory value of SCEA vary from 150 to 300, for
general machining. The shape of the workpiece will also determine the SCEA. To produce a
shoulder, zero degree SCEA is needed. No SCEA is desirable when machining casting and
forgings with hard and scaly skins, because the least amount of tool edge should be exposed
to the destructive action of the skin.

End cutting-edge angle (ce): The end cutting edge angle provides a clearance or relief to
the trailing end of the cutting edge to prevent rubbing or drag between the machined surface
and the trailing part of the cutting edge. Only a small angle is sufficient for this purpose. Too
large an ECEA takes a way material that supports the point and conducts away the heat. An
angle of 80 to 150 has been found satisfactory in most cases on side cutting tools, like boring
and turning tools. The flat 1.5 to 7 mm long is ground on the front portion of the edge next to
the nose radius to level the irregular surface produced by roughening tool.

Side Relief angle or Clearance angle (𝜽𝒔 ):

When the slope is given download from cutting edge. That is divided in two types of
clearance angle. They are

• Side relief or side clearance angle

• End relief or end clearance angle
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 The angle between side of Flank and perpendicular line to tool base, it is known as side
relief angle. Which is provided to help of avoid rubbing when tool is feed sideways into job. In
case the side relief angle is large, the Tool cutting edge will be breakdown because of insufficient
support. So it will be avoid the side relief angle is having very small.

When the cutting tool cannot be feeding into the work job. but it also rubbing against the
job. So the overheating of tool will be done. This reason to affect the job surface finish.
The angle between flank of end and line perpendicular to tool base measuring along right angle
to flank of end is called as and relief angle. This angle is used to prevent the cutting tool from
rubbing again work job. If the relief angle is very large, it will be break down due to insufficient
support of cutting tool. So the cutting of job will not be properly and the poor surface finish will
be done. For generally it angle from 6 degree to 10 degree. So it provided in very small angle.
Cutting edge angle:
The cutting edge angle having two types such as side cutting edge and end cutting
edge. The side cutting edge angle is the angle between side of cutting edge and side of tool Shank.
Alternatively, the angle between side of cutting edge and longitudinal axis of tool. It side cutting
edge used to control the flow of chip, avoid the formation of built up edge and distributing of
cutting force.
The end cutting edge angle is the angle between end of cutting tool and line of
perpendicular to tool Shank. Alternatively, the angle between tool face and plane perpendicular to
shank side. Allow only for small question of end section edge to contact the machining surface,
and also the vibration and chatter are prevented. The angle will be from 5 degree to 15 degree.

Nose radius:
The nose radius is the angle between side of cutting edge and end of cutting edge.
Which the side cutting edge and end cutting edge to joining a line by point lead to high heat
concentration. When the joining by means of the small radius is good configuration to increase
in the cutting tool life and to obtain better surface finish. By the large radius, strengthening the
tool and it used on cast iron and also the casting where the cuts are interrupted.

Fig:4.1: Nose radius

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 Fig:4.2 : Nomenclature of single point cutting tool
4.2 Turning inserts identification:
1. Insert shape
2. Relief angle
3. Tolerance class
4. Chip breaker and clamping system
5. Insert size
6. Insert thickness
7. Insert corner configuration
Cutting edge condition
8. Cutting direction
9. Chip breaker

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 Fig: 4.3: Insert shape & relief angle

Fig:4.4 : Tolerance class

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 Fig:4.5 : Chip breaker and clamping system

Fig:4.6 : Insert size and thickness

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 Fig:4.7 : Insert corner configuration

Fig:4.8 : Chip cutting Direction

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 4.3 The turning inserts used in this project:
1. PSDNN
1. PSDNN
• Lever lock type
• ISO standard

Fig:4.9 : PSDNN cutting tool

2. PRSCL

Fig: 4.10 : PRSCL cutting tool

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 4.4 Speed, feed, net power calculation
Speed, feed, net power calculation for BH1:
Depth of cut (ap) = 10 mm
Tool feed (𝑓𝑛) = 0.8 mm/rev
machine efficiency (ή) = 75%
Cutting force on tool (kc) = 2300 N
𝜋×𝐷×𝑁
cutting speed(vc) = 1000
𝜋×850×30
= = 80.11 m/min
1000
𝑣c×𝑎𝑝×𝑓𝑛 ×𝑘𝑐
Net power (pc) =
60×1000×ή
80.11×10×0.8×2300
= = 32.756 kw
60×1000×0.75

Length of the job to be turned

Machining time (T) = Feed×RPM
1200
= = 50 min
0.8×30

d Fig:4.11 : BH1 profile

Speed, feed, net power calculation for modified BV3:
Depth of cut (ap) = 10 mm
Tool feed = 0.8 mm/rev
machine efficiency = 75%
Specific Cutting force (kc) = 2300 N
𝜋×𝐷×𝑁
cutting speed(vc) = 1000
𝜋×730×30
= = 68.80 m/min
1000
𝑣c×𝑎𝑝×𝑓𝑛 ×𝑘𝑐
Net power (pc) =
60×1000×ή
68.80×10×0.8×2300
= = 28.13 kw
60×1000×0.75

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 Length of the job to be turned
Machining time (T) = Feed×RPM
1000
= = 41.66 min
0.8×30

Fig:4.12 : BV3 profile

• The machining time for BH1 roller is = 50 min, but the modified BV3 roller machining
time is = 41.66 min.

1.Discontinuous Chips:
Cast iron, hard brass and other materials that produce discontinuous chip. Discontinuous or
segmented chips are produced when brittle metal such as cast iron and hard bronze are cut or
when some ductile metals are cut under poor cutting conditions.
The point of the cutting tool contacts the metal, some compression occurs, and the chip
begins flowing along the chip-tool interface. As more stress is applied to brittle metal by the
cutting action, the metal compresses until it reaches a point where rupture occurs and the chip
separates from the unmachined portion. The cycle is repeated indefinitely during the cutting
operation, with the rupture of each segment occurring on the shear angle or plane. The result
of these successive ruptures, a poor surface is produced on the work piece. The chips are
deform and begin to break up at a problem when machining these materials. Harder ,more heat
and wear resistant carbide grades can be used in these applications. Edge strength becomes less
of a factor to machining steel, stainless or other materials that make long chips.

Fig:4.13 : Discontinuous Chip

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 2. Continuous chip:
Medium to high carbon and alloy steels materials that produce continuous chip.
Continuous chips are a continuous ribbon produced when the flow of metal next to the tool face
is not greatly restricted by a built-up edge or friction at the chip tool interface. The continuous
ribbon chip is considered ideal for efficient cutting action because it results in better finishes.
Unlike the discontinuous chip, fractures or ruptures do not occur here, because of the ductile
nature of the metal.
When machining these type of metals with carbide inserts the material in front of the
cutting edge deforms resulting in high temperatures which softens the metal and consequently
lowers it’s strength and hardness making it easier to machine. In some cases, air, oil or coolant
quenches the hot chips, hardening them and making them brittle and easier to break. The chips
produced when cutting these metals contact the face of the tool behind the cutting edge creating
a zone of high heat that can result in cratering. Coating usually eliminates this problem.

Fig:4.14 : Continuous Chip

3.Sheared chips:
Low carbon steels, stainless steels, nickel alloys, titanium, copper, Aluminium and
other soft materials . Sheared chips refer as continuous chip with a built-up edge . The metal a
head of cutting tool is compressed and forms a chip which is begins to flow along the chip-tool
interface. The high temperature, the high pressure, and the high frictional resistance against the
flow of the chip along the chip-tool interface, small particles of metal begin adhering to the edge
of the cutting tool while the chip shears away. The cutting process continues more particles
adhere to cutting tool and a larger build-up results, which affects the cutting action. The built-
up edge increases in size and becomes more unstable. The build-up and break down of the built-
up edge occur rapidly during a cutting action and cover the machined surface with number of
built-up fragments. These fragments adhere to and score the machined surface, resulting in a
poor surface finish.

Fig:4.15 : Sheared Chip

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 4.5 CUTTING FLUIDS:
In any metal cutting operation lot of heat is generated due to: plastic deformation
of metal, friction at the rack face of the tool between the tool and the chip and also the friction
between the work piece and the flank of the tool. This increases the temperature both of the
work piece and the tool point, resulting in decrease in hardness and hence life of the tool. The
machined surface will also be rough and the possibility of built up edge increases so, the use
of cutting fluid during a machining operation is very essential. Its application at the work
piece-tool interface produces the following effects:
a. Friction at the work piece-tool interface is reduced, due to lubrication action.
b. Heat is reduced due to cooling action at the interface.
c. Chips are washed off
So, the cutting fluid performs the following functions
a. Reduces heat generation.
b. Provides lubricating action.
c. Carries away the heat generated and so provides cooling action, thus, reducing work
piece temperature and distortion.
d. Provides flushing action in washing off the chips and swarf.
e. Reduces friction and wear, which improve tool life and surface finish.
f. Reduces force and energy consumption.
g. Protects the newly machined surface from environmental corrosion.
h. Prevents surface welding of points at high pressure, thus, controlling formation of B.U.E.
i. Facilitates chip breaking in certain materials.
4.5.1 Lubrication and cooling Action of cutting fluids:
During metal cutting, the area of contact between tool and job is very large and
also the ratio of real to apparent area of contact is very nearly equal to unity. Again, the
contact pressure at the tool-work piece interface is very high. Due to the above two factors,
the type of lubrication in metal cutting can never be full fluid film lubrication. It Can only
boundary lubrications. Because of this, the chemical properties of a cutting fluid are more
important than its physical properties.
4.5.2. Requirements of A Cutting Fluid:
A Cutting fluid should have the following properties:
a. It should wet the surfaces of cutting tool and workpiece for better cooling and lubricating
effects.
b. Good lubricating property.
c. High heat absorbing capacity.
d. High flash point.
e. It should not stain or leave residues on the workpiece surface.
f. It should not emit toxic vapour.
4.5.3. Types of cutting fluids:
There are basically two main types of cutting fluids:
1. Those which are mixed with water, such as, soluble oil and soaps. There are emulsion of
oil and water or soap and water.
2. Those which are not mixed with water, called cutting oils, which can be pure oils or a
mixed of two are more oils.

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 soluble oils:
Water increases the cooling effect and oil provides the best lubricating properties.
by mixing various proportions of water with soluble oils or soaps, cutting fluids with a wide
range of cooling and lubricating properties, can be obtained. The ratio of oil to water depends
upon the application of the cutting fluid and range about 1:5 to 1:50. The usual ratios for the
various machining operations can be:
Turning : 1:25;
Milling : 1:10;
Drilling : 1:25;
Grinding : 1:50
Cutting oils:
These are mixed oils and mineral oils. Fixed oils consist of animal, fish and vegetable
oils. Chiefly used fixed oils are: lard oil, sperm or whale oil, and olive, cotton seed and linseed
oil. Turpentine oil distilled from vegetable oils is also used. Fixed oils have greater oiliness
than mineral oils but are not So stable as mineral oil and tend to become gummy and decompose
when heated. Mineral oils come from crude petroleum oils, for example, paraffin.

4.5.4. Application of cutting fluids:

The cutting fluid may be applied to be the cutting tool in the following ways:
1. By hand, using a brush.
2. By means of a drip tank attached to the machine body.
3. By means of a pump.
For the effective use of cutting fluid and for heavy and continuous cutting, the fluid should
penetrate into the cutting zone. For this, the third method of supplying the cutting fluid is the
most common. This is known as “flood application”. Here, a continuous stream of cutting
fluid is directed at the cutting zone with the help of nozzle or jet. this is also known as “hi-jet
method”. The used cutting fluid drops into a tank at the bottom. Before it, is recirculated by
the pump, it passes through many filters to remove chips and dirt. To avoid excessive
splashing and vapourization of the fluid, it is supplied to the cutting zone from the top also,
for some Application, the cutting fluid is supplied through the tool itself and directed along
the flank face of the tool.

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 CHAPTER :5

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 CNC Roll Turning Lathe Machine

5.1 BAR MILLS:-

Bars and wire rods are known for the long subsequent processing they undergo
in the secondary and tertiary processors until the final end products are produced.
Furthermore, as such end products are used in many cases as vital parts in various industrial
fields ,efforts for process rationalization in integrated collaborations with customers are
incessantly sought for to date, each rolling mill, belonging to the Bar and wire Rod Division
has tackled the introduction of in-line heat treatment facilities and development of small-
diameter wire rods and controlled rolling with the goal of omitting certain steps, improving
productivity, and energy saving.
In recent years, amid the ever-growing intense competition with overseas suppliers
and with the intention of establishing stronger competitiveness in product quality by improving
dimensional accuracy and product metallurgical quality, efforts to improve equipment and
operations are being promoted.

Fig:5.1 : Bar mill

These type of bar mills are used in steel plant for compressing the bars in BILLET
MILL department they have different stages and different size according to the order of the
consumer.

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 5.2 CNC LATHE MACHINE :-
5.2.1 INTRODUCTION :
Computer numerical control ( CNC ) has been incorporated into a variety of new
technologies and machinery. One such machine of this sort that is used for a wide array of
production processes is known as a CNC lathe.
Due to technological advancements, CNC lathes are quickly replacing some of the older
and more traditionally used production lathes, such as the multi spindle. CNC lathes comes with
a number of benefits. They can be easily set up and operated. They offer tremendous
repeatability, along with top-notch accuracy in production.
A CNC lathe is typically designed to utilize modern versions of carbide tolling and
processes. A part can be designed for customization, and the machine’s tool paths are often
design a part or tool path as well. The resulting coded computer file is then uploaded to the CNC
machine, and the machine will then automatically produce the desired parts for which it was
programmed to design.

Fig:5.2 : CNC lathe machine

A CNC lathe is controlled by a menu-type interface on a computer. The operator who

manages the process can actually see a visual simulation of how the machine will function
during the production phase.

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 5.2.3 HISTORY OF CNC
INTRODUCTION TO NUMERICAL CONTROL:
Numerical control (NC) was developed in 1950 to meet the critical requirements
of Aerospace industry. Many components used in aircraft and apace vehicles have
complicated features. In order to do machining these components with conventional
machine tools, it requires number of positioning movements of the machine tool slides.
Manual operation under these circumstances is not only tedious but also less efficient,
unproductive and mostly the part is likely to be rejected due to machining errors. So
numerical control was developed for automation of machine tools. Automation of machine
tools means controlling the machine tool without an operator assistance. As a part of the
automation the information required to activate and control slides was coded numerically,
this technology came to be known as numerical control.

5.2.4 NUMERICAL CONTROL:

The numerical control is the operation of machine tool or a process by a series of coded
instructions comprising of numbers, letters and other symbols to carry out specific task.

COMPONENTS OF NC SYSTEM:
The NC system has three components basically
a) Program of instructions
b) Machine control unit
c) Machine tool

Fig:5.3 : Components of NC system

PROGRAM: A program is a set of instructions which informs the machine tool what is to be
done and when it is to be done. A program prepared for a part is called part program. In NC
system part program was coded on a punched tape, punched cards or magnetic tape.
Punched tape:
The punched tape used for NC is 1 inch wide. In manual part programming a
punched tape is prepared by type writer like device. In computer assisted part programming tape
is prepared directly by the computer using a device called a tape punch. The punched tape uses
coded symbols which represent the part program and the controller unit must be capable of
reading thee symbols.

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 Fig:5.4 : Punched tape machine
Tape coding:
The punched tape have 7 bit code in a 8 track format with 5 reserved for parity check. Paritytrack
is a device for error checking and to ensure that the tape has been punched correctly.
The digit 1 to 9 are punched as binary equivalents. The digit 1 equivalent to binary 1 and digit 2
is equivalent to binary 10 and so on. Alphabetical characters are divided into 3 groups. A to I all
have holes punched in tracks 6 and 7. J to R all have a hole punched in track 7 and S to Z have a
hole punched in track 6. Delete is recognised by hole in every track.

Fig:5.5 : Tape coding

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 5.2.5 NC Words:
The combination of binary digits in a row on tape denotes a character. A NC
word is a collection of characters. The collection of NC words is called a block. The block
of NC words is a complete NC instruction. Following are the NC-words used in the
formation of block.
1. Sequence Number (N-Word): The first word in every block is the sequence number.
It is used to identify the block. The sequence number is preceded by word N and is
written as N0001,N0002,N9999 etc. The programme is executed from lowest block.
2. Preparatory function ( G- Words): The preparatory word prepares the control unit
to execute the instructions that are to follow. The preparatory function is represented
by two digits preceded by G i.e., G00……G99.
3. Coordinates( x, y and z words) : These words give final coordinate positions for x,
y, z motions. In two axis CNC system only two-co ordinate words would be used.
4. Feed function (F- word ): The feed function is used to specify the feed rate in the
machining operation. The feed rate is expressed in mm per minute or mm/rev. If the
feed is 200mm/min, it will be represented as F200. The corresponding G-codes will be
G-94.
5. Spindle speed function ( S-word): The spindle speed is specified either in
revolutions per minute (r. p. m) or metres per minute. If the machine is required to run
at 800 rpm the speed will be specified as S 800
6. Tool selection function (T- word): The T- word in the part programme specifies
which tool is to be used in the operation. The tool number for a particular operation is
specified as T00 to T99.
7. Miscellaneous Function (M- word) : The Miscellaneous function word is used to
specify certain miscellaneous or auxiliary functions which do not relate to the
dimensional movements of the machine. The miscellaneous functions may be spindle
start, spindle stop, coolant ON/OFF etc.
8. End of Block (EOB): The EOB symbol identifies end of instruction block.

5.2.6 MACHINE CONTROL UNIT ( MCU):

The machine control unit is an electronic system which includes tape
reader, data buffer, signal channel.
• A tape reader is an electromechanical device for winding and reading punched tape
containing the part program instructions.
• The data available on the tape is read into the data buffer which is a device to store the
input instructions .
• Signal output channels are linked to the control mechanism of machine tool. The
instructions stored in data channels. If the instructions have been properly executed by
machine tool a feed back data is sent back to MCU through feed back channels.
5.2.7 MACHINE TOOL:
Machine tool is the another basic component of an NC system. It performs
the useful work. It consists of work table, spindle and motors which are driven and controlled
by the signals from MCU. Some of the machine tools that are built on NC system are turning.

Tool compensation:
Tool compensation ensures that programming is independent of tool
dimensions. The tool length compensation and tool nose radius compensation are stored in the
memory of control system.
• Tool Length Compensation: When

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 5.2.8 CNC ,MKNN ,MJN NJJ PARTS :-
1. Chuck
2. Tail-stock
3.Carriage
4.Head stock
5.Pendant / Control panel
6.Turret
1.CHUCK:
CNC lathe machine chuck grips the component which are to be machined. Chuck itself
has many parts. Jaws are mounted on the chuck to grip the part.
2. TAIL STOCK :
Tailstock is mostly used to extra gripping force for component machining. For long
components machining they provide extra force on the other end so machining process can
complete smoothly. At the one end chuck is gripping the component and on the other end
tailstock is providing the extra force.
3. CARRIAGE:
The bed is actually the base of the headstock and it allows connects to it. The bed
helps set the carriage and the tailstock in perfect parallel alignment to the spindle axis. A part
called a way holds the carriage and the tail stock on to the track. The carriage travels a long
the machine using a rack and pinion system. It also include a leadscrew that keeps it on an
accurate pitch or it has a feed screw.
4. HEADSTOCK:
Headstock of a CNC lathe machine have the main motor of CNC lathe machine which
drives the main spindle. Chuck is mounted on this main spindle.
5. PENDANT / CONTROL PANEL:
The CNC machine program are stored inside the panel. The CNC machine is control
through the keys on this panel. CNC machinists start/stop the machine move axis by pressing
different keys on this panel. They can enter new program by using this panel, program can
be transferred by using USB port on this panel as well. So this is the main part which controls
the whole CNC machine.

5.3 CLASSIFICATION OF NC SYSTEM :

1. Based on control system features:
a. Point to point NC system.
b. Straight line NC system.
c. Continuous path of contouring NC system.

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 2. Based of feedback:
a. Open loop NC system.
b. Closed loop NC system.
3. According to the structure of control circle:
a. Analogue control NC system.
b. Digital control NC system.

5.4 MACHINE CONTROL UNIT ( MCU) :

Every CNC machine is fitted with a machine control unit which may be housed in a
separate panel, mounted in the machine itself or be housed in a pendant which can be swung
around the machine. The MCU perform the following function.
a. Ancillary function: concerning machine operation like machine tool spindle start/stop,
vary spindle speed, charge the tool, lock or unlock fixtures ,work pieces.
b. Positional (Dimensional ) control :To guide the cutting tool tip along the desired path
by controlling the displacement of slide members and rotation of circular tables.
c. Feed rate control: By inputting the required data to the tap the feed back may be
controlled.

5.5 INPUT MEDIA FOR MCU:

In any NC machine tool system, the information required to produce a part has to be
converted into a binary alphanumeric code that can be read by the NC system. The converted
information must be stored in a storage device, in such a way that it would be ready when
called upon bye the NC system. The storage device can be punches tape, a magnetic tape, a
floppy disc, a command plug board or may be directly input to the computer memory.

5.6 CNC TOOLING:

The operator is supplied with the relevant cooling for the part to be machined. The
unique deviation of the CNC tooling from that or the conventional one is that each cutting
tool is set in a different adapter. For long range objectives of maintaining accuracy and of
course, convenience also, the tooling is usually stacked on a shelf oil trolley or may be placed
on the drum which is operationally an integral part of the machine tool itself.

5.7 ADVANTAGES:-
1. An increase in flexibility.
2. The reduction in hardware circuits and simplification of the remaining hardware, as well
as the availability of automatic diagnostic program entails a need for fewer maintenance
personnel.
3. A reduction in inaccuracies I manufacturing due to a reduce use of taper reader.
4. An improvement in the possibilities for correcting error in path programming an editing
feature.
5. The possibility of using the computer’s peripheral equipment for debugging the edited
part-data tape. EX A plotter of C.R.T can be used drawing shape of the part.
6. CNC greatly reduces the number of control board required and also the inventory of spar
boards.

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 5.8 HOW DOES CNC WORKS:
1. A sequence of operations leading to the machining of a part in point to point position..

2. The necessary information for numerical control can often be extracted from the
engineering drawing with little (or) no calculation for this purpose, the part is considered
as being in a quadrant of rectangular co-ordinates. The dimensions of all the important
details are given from the data point X&Y axis.

3. The information is listed on a format known as manuscript. The manuscript describes the
X&Y positions of each hole, the sequence in which the hole are to be auxiliary functions
like coolant on and off (or)clamping and unclamping the part.

4. After the manuscript is prepared, the information has to be kept in hard disk of
programming transfer unit consisting DNC system to the control medium which is done on
some automatic writing and tape performing machines.

5.9 OPERATION OF CNC LATHE MACHINE:

5.9.1 INTRODUCTION:
For CNC lathe machines it is must to know their controllers and its functions. The next
step is to know how to load the work piece and which tool has to use and how to perform the
work and how to unload the work. In CNC machine we are using NC part program for
machining the work piece. By feeding the program to CNC and running the program machine
itself perform the work.
Here first of all we have to decide which type of profile has to machine. After deciding
that the program. This program is down loaded to CNC lathe machine from programming room
with reference to program the operator will decide which type of tool has to use this because
the type of tool to used is also indicated in the program. So the operator on the CNC lathe.
After , that the operator is to set the reference point to the cutting tool with respect
to work piece. Next the operator calls the required and engages the tool with work piece and
starts the program ,while running the program the work can be performed here the operator has
to decide how much depth of cut into give. After completion of work the work piece can be
checked with template for accuracy.

5.9.2MAIN OPERATION AND CONTROL ELEMENTS :

The operating and control elements for the machine functions are located in the
control station on the carriage. Additional operating panels for the respective partial functions
are situated at the control cabinet, head stock, and tailstock.

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 5.9.3 CONTROL CABINET:

Fig:5.6 : Control Cabinet

5.9.3 Main Switch Drive:

When switch on the machine control is control is connected to the power supply.
At the end of the shift (or) when maintenance work is to be done at the electrical system, the
main switch should be switch off.

5.9.3.2 Main Switch Control :

For CNC measuring systems and control. When switched on the CNC and control
parts are connected to the power supply when switched off, all data stored in the CNC are
lost. If at the end of the shift, data is still stored which is required to continue machining, this
switch should not be switch off. Switch off this however necessary when maintenance work
is to be carried out on the CNC.

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 5.9.3.3 Voltage control of the power supply:
Line voltage display the available current potential.

5.9.3.4 Current control of the power supply:

Line current display the available strength of current.

5.9.3.5Working Hour Meter:

This display is activated, when the main switch is switched on.

5.9.3.6 Emergency stop:

Use when danger occurs, all running elements stopped immediately.

5.10 MAIN CONTROL STATION AT THE CARRIAGE

5.10.1 Display devices :
Spindle load - Load of the headstock drive in A%
Spindle speed - Main spindle speed in rpm.
Feed X - X-axis feed in mm/min
Feed Y - Y-axis feed in mm/min

5.11 OPERATING ELEMENTS FOR MACHINE CONTROL

5.11.1 Machine off:
The machine control is activated via this key-operated switch. Any CNC-programs in the
memory will be held at position off.

5.11.2 Machine -1:

This illuminated button is activated to switch the machine on. The button flashes at first .
It doesn’t turn the machine is ready to operate.

5.11.3 Hold all Motions :

Activation of this illuminated button causes all running drives to stop, pump and
ventilators carry on working.

5.11.4 NC -MAN:
When the selection switch is in the NC position the machine can be operated automatically
(or) in adjustment mode via the CNC operation elements. This can be switch over when the
feed axis and the main spindle are at a standard still. In MAN position, all machine functions,
feedback and speed are controlled via the manual operating plane.

5.11.5 Error:
The lamp light up to show the respective condition. This enables the condition to be
localized via digit display in the CNC part of the control station.

5.11.6 Diagnosis-Display:
Errors and operating message are displayed by digits.

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 5.11.7 Data Display Unit :
When operating in CNC-mode the occurred situation will be displayed on the display unit.

5.11.8 Fault Rest:

The lamp in the button flashes when as error occurs and stays on continuously when an
operating message (or) operator error occurs. After rectifying the error message are automatically
extinguished.

5.12 HEAD STOCK

The head stock carries the main spindle, which is in double-row cylindrical roller bearings.
It is driven by a 2-speed gear with direction of rotation the spindle in clockwise. When locking
towards the face plate. With direction of rotation the spindle rotates counter-clockwise, when
locking towards the face plate. The respective lamps lights up to indicate the selected direction
of rotation and the engaged gear speed.

5.12.1 Spindle speed:

The correct selection of the spindle speed is essential for the economic running of the
machine. The speed depends on the tool and the work piece, as well as the surface quality
required. The speed ranges are set by M-functions in the CNC mode, and by the operating
elements at the control station in MANUAL mode.
1. Set MANUAL mode of operation.
2. Set gear transmission speed for the required speed range.

Table:1

M - SPEED RANGE
SPEED FUNCTION
1 M-41 1.0-83 RPM

2 M-42 6.0-500RPM

The engaged gear transmission speed is indicated by the respective lamp in the illuminated
push button.

Switch on the main spindle using the button. After the button has been passed,the spindle
rotates at the speed set.
1. Regulation of the speed on the potentiometer SPEED.
2. Switch off the main spindle using push button ‘O’.

If a drive is running when switch off is carried out the feed drive is switched off first of all
and them, after a few rotations, the spindle stops so that the tool can cut itself free. The
adjustment purpose, the main spindle can also be switched on using the buttons JOG. The
spindle rotates at a certain speed for as long as the button is held depressed.

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 5.13 TAIL STOCK
Adjustment on the bed, the tail stock can be adjusted on the bed by a 2-speed fine feed
motor. The high speed 2800mm/min is used to bridge the long distance to the work piece.
The low speed 60mm/min is used to travel the tail stock with the centers up to the work
piece(or) respective to the work piece(or) respective the within few mm of the work piece
where it is then clamped. The adjusting motor is stopped by means of a contact in pressure
measuring system when an approach force of approx..10KN is reached preventing damage to
the machine due to a great thrust force.

5.13.1 Adjustment of the centre shaft :

The live centre can be extended up to 10mm and can be positioned against the work piece
with the required axial force. Limit switches prevent travel beyond the end positions. The axial
force of the centre is indicated on, each gauge at the front(or) back of the tail stock. A Belleville
spring washer stack compensates any changes in length of the work piece resulting from
temperature fluctuations
.

5.13.2 Lubrication:
The central lubrication for the tail stock works automatically. As long as one of the
adjustment motors for the tail stock is running ,all lubrication points receive an exact dosage of
the oil at given intervals. After a longer period of disuse additional lubrication pulses should be
introduced by pressing the button lubrication pulse on the control panel.

5.13.3 clamping of work piece between the centers :

1. Move the work piece into the centre at the head stock is side.
2. Travel the tailstock with retracted live center until it stands 0 to 5 mm from the work piece
and then clamp.
3. Set the indicator force at the contact pressure gauge in accordance with the following table
depending on the weight of the piece.
4. Travel the live centre into the work piece centreing. When the set axial force has been
reached the force measuring system switched off the adjustment motor.

5.14 TURNING CARRIAGE

The machine is equipped with one turning carriage. The top carriage is designed as a
4-sation turret head. The 4 stations can be equipped with turning (or) boring tools. To produce
exactly dimension work piece it is recommended to measure the tool in the holder in a tool
setting device and to input the dimensions X and Z and the cutter radius into the control over
the keyboard on the CNC operating panel. For pieces with the very small dimension
tolerances,it may not be possible to achieve the required dimension accuracy with the tool pre-
setting the device. In such cases, a measuring surface is machined as a reference, this is then
measured with a micrometer gauge and if necessary, the tool offsets input over the CNC. All
carriage functions , with the expectation of the tool mounting, can be introduced over the CNC
operating panel(or) over the manual operating buttons on the main control station.

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 5.15 SERVICE PANEL AT THE CONTROL CABINET
The panel can be locked using a glass door and should not be accessible to un-
authorized persons.
1. 220 V NC/S5 : The lamp illuminates when the supply voltage fails.
2. Faults : the lamp flashes when error occurs and shows continuous light when a message
is displayed.
3. Emergency limit switch bridged : This button must be activated to release the axis
when it has reached an emergency limit switch.
4. NC ON-OFF : When operating in CNC -mode the pre-selections switch must be turned
to ON.

5.16 SERVICE PLANE

1. Release : The service plane is activated by using this key-operated switch.
2. Input/memories/outputs: For selecting the respective address mode.
3. Inputs: The adjustment of the decade switch and the information from the message amp
indicate an input.
4. Memories : For selecting markers; the decade switches denote a marker.
5. Outputs : The adjustment of the decade switch and the information from the message
lamp indicate an output.
6. Pre-selection with 4 decades: These 4 switches are used to pre-select the number of the
pre-selected input/marker/output. The byte-address is 3-digits, the bit-address is given with
one digit.
7. Setting : This button is used to set the selected output(or)marker. The lamp dis-players
the selected output ,input(or)marker.
8. Erasing : This button is used to erase the selected output (or) marker.

5.17 CODES
5.17.1 G-Codes:
G-codes are preparatory functions which involves actual tool moves. These include rapid
moves, feed moves, radial feed moves, dwells and roughing and profiling cycles. A few of the
usual preparator functions which are generally present in all machining centers are uniformly
followed. These are listed below

5.17.2 Motion Group :

G 00 Rapid positioning
G 01 Liner Interpolation
G 02 Circular Interpolation clock wise
G 03 Circular Interpolation counter clock wise

5.17.3 Dwell:
G 04 Dwell

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 5.17.4 Active Plane Selection group:
G 17 XY plane selection
G 18 XZ plane selection
G 19 YZ plane selection

5.17.5 Cutter compensation Group:

G 40 Cutter Compensation cancel
G 41 Cutter radius Compensation, left
G 42 Cutter radius compensation, right

5.17.6 units Group:

G 70 Inch units
G71 Metric units

5.17.7 Hole making Carried cycle Group:

G 80 Canned cycle Cancel
G 81-G 89 Canned cycle definition and ON

5.17.8 Coordinate System Group:

G 90 Absolute Coordinate system
G 91 Incremental Coordinate system

5.17.9 Pre-set :
G 92 Absolute pre-set, change the datum position

5.18 M-CODES
M-codes are miscellaneous functions which include actions necessary for
machining but not those that of actual tool movements. That is they are auxiliary functions, such
as spindle on and off, tool changes, coolant on and off, program stops and other similar related
functions. Some common miscellaneous functions supported by all controller are

5.18.1 Group-1:
M 00 Program stop
M 01 Optional program stop
M 02 End of program
M 17 End of subprogram
M 30 End of program with rewind

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 5.18.2 Group-2:
M 03 Spindle direction clock wise
M 04 Spindle direction counter clock wise
M 05 Spindle stop

5.18.3 Group-3:
M 36 Feed rate as programmed under F
M 37 Feed rate reduced 1:100

5.18.4 Group-4:
M 06 Change of tool
M 20 Turret position 0 Degrees
M 21 Turret position 90 Degrees
M 22 Turret position 180 Degrees
M 23 Turret position 270 Degrees
M 31 Turret without spindle
M 41 Gear 1 1-83 rpm
M 42 Gear 2 6-500 rpm
M 88 Mirror Z-Axis ON
M 89 Mirror Z-Axis OFF

5.19 PRECAUTIONS TO BE TAKEN IN OPERATION:-

1. Prior to its initial run, the machine must be thoroughly cleaned and all the foreign objects
not belonging then must be removed.
2. Please ensure that all hydraulic devices are functioning properly.
3. While operating the machine you familiarize yourself with all operating and controlling
elements and carry out a short no load run before the machine in put into preparation.
4. Immediate loading of the machine should be avoided.
5. When travelling the carriage with the units extended, either in manuval(or) in CNC mode
ensure the collision with the head stock and the tail stock and the work piece does not occur.
6. A change of gear speed may only be made when the main spindle in at a stand till, for
unbalanced work piece, the centre(or) gravity must always be at the button when changing
gear speeds.
7. When ever loading the work piece the adjustment of tail stock may be done. While adjusting
the tail stock the axial force should not exceed 10 K.N . In case the axial force may be
increased above 10 K.N a message is given, in this case reduce axial force.

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 5.20 CNC PROGRAMMING
5.20.1 Introduction :
The term numerical control is a widely accepted and commonly used terms in the machine
tool industries. Numerical control (NC) enables an operator to communicate with the machine
tool through a series of number and symbols.NC which quickly become computer numerical
control(CNC) has brought tremendous changes to the metal working industry. New machine
tools in CNC have enable industry to consistently produces parts.
CNC is a vast improvement over non-computerized machining that must be manually
controlled(e.g., using devices such as hand wheels or levers ) or mechanically controlled by
prefabricated pattern guide(cams).In modern CNC systems, the design of a mechanical part and
its manufacturing program is highly automated. The parts mechanical dimensions are defined
using CAD software and then translated into manufacturing directives by computer- aided
manufacturing (CAM) software.
The resulting directives are transformed (by “post processor” software) into
the specific commands necessary for a particular machine to produce the component, and then
are loaded into the CNC machine. Since any particular component might require the use of
a number of different tools drills, saws, etc. Modern machines often combine multiple tools
into a single “cell” In other installations ,a number of different machine used with an external
controller and human or robotic operators that move the component from machine to machine.
In either case, the series of step needed to produce any part is highly automated and produce a
part that closely matches the original CAD.

5.20.2 Cartesian Co-ordinate system:

A Cartesian coordinate system is a coordinate system that specifies that specifies
each point uniquely in a plane by a set of numerical coordinates, which are the signed distances
to the point from two fixed perpendicular oriented lines, measured in the same unit of length.
Each reference line is called a coordinate axis or just axis (plural axes) of the system, and the
point where they meet is its origin, at ordered pair (0,0).
The coordinates can also be defined as the positions of the perpendicular
projections of the point onto the two axes, expressed as signed distance from the origin.
The invention of Cartesian coordinate in the 17th century by Rene Descartes
revolutionized mathematics by providing the first systematic link between Euclidean geometry
and algebra. Using the cartesian coordinate system, geometric shapes can be described by
Cartesian equations algebraic equations involving the coordinates of the points lying on the
shape. For example, a circle of radius 2, centred at the origin of the plane , maybe described as
the set of all points whose coordinates x and y satisfy the equation x2 + y2 = 4.
We mentioned illustration of a Cartesian coordinate plane. Four points are marked
and labelled with their coordinates : (2,3) in green, (-3,1) in red, (-1.5,-2.5) in blue ,and the
origian (0,0) in purple.

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 Fig:5.7 : Cartesian co-ordinate system
5.20.3 One dimension :
Choosing a Cartesian co-ordinate system for a one -dimension space that is, for a straight
line involves choosing a point ‘o’ of the line(the origin), a unit of length, and an orientation for
the line. An orientation chooses which of the two half-lines determined by 0 is the positive,
and which is negative ;we then say that the line is “oriented” from the negative half towards
the positive half. Then each point ‘p’ of the line can be specified by its distance from O, taken
with + or – sign depending on which half-line contains P.

5.20.4 Two Dimensions:

A Cartesian coordinate system in two dimensions also called a rectangular
coordinate system or an orthogonal coordinate system is defind by an orientation for each axis.
The point where the axis meet is taken as the origin for both. Thus turning each axis into a
number line. For any point p, a line is drawn through perpendicular to each axis ,and the
position where it meets the axis is interpreted as a number. The two numbers, in that chose
order, are the Cartesian coordinates of P. The reverse construction allows one to determine the
point ‘p’ given coordinates .
The first and second coordinates are called the abscissa and the ordinate of ‘P’,
respectively and the point where the axis meet is called the origin of the coordinate system. The
coordinate arc usually written as two number in parentheses, in that order, separated by a
comma, as in (3,-10.5) . Thus the origin has coordinates (0,0), and the points on the positive
half-axes, one unit away from the origin, have coordinates ( 1,0) and (0,1).

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 Fig:5.8 : Two Dimensions system

5.20.5 Three Dimensions :

Fig:5.9 : Three Dimensions system

A three dimensional Cartesian system, with origin 0 and axis lines X ,Y and Z, oriented as
shown by the arrows. The tick marks on the axes are one length unit apart. The black dot shows
the point with coordinates x=2,y=3and z=4 or (2,3,4).

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 A Cartesian coordinate system for a three-dimensional space consists of an ordered triplet
of lines that go through a common point , and are pair-wise perpendicular, an orientation for
each axis, and a single unit of length for all three axes. As in the two-dimensional case, each
axis becomes a number line. For any point P of space, one considers a hyperplane through P
perpendicular to each coordinate axis, and interprets of P are those three numbers, in the chosen
order. The reverse construction determines the point P given its three coordinates.

5.20.6 Distance between two points :

The Euclidean distance between two points of the plane with Cartesian coordinates (x1,y1)
and (x2,y2) is

D = √(𝑥2 − 𝑥1 ) 2 + (𝑦2 − 𝑦1 ) 2

This is the Cartesian version of Pythagoras’s theorem. In three- dimensional space,

the distance between points (x1, y1, z1) and (x2, y2 ,z2) is

D = √(𝑥2− 𝑥1

5.20.7 Programming system:

Two types of programming modes, the incremental system and the absolute system,
are used for CNC. Both systems have applications in CNC programming, and no system is
either right or wrong all the time. The controls on machine tools today are capable of handling
either incremental or absolute programming.

Positioning
Reference Point system

Incremental Absolute

Fig:5.10 : Programming system

Incremental program location are always given as the distance and direction from
the immediately preceding point codes which tell the machine to move the table, spindle, and
knee are explained here using a vertical milling machine as an example.

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 Fig:5.11 : Example for incremental system
1. A “X plus ” (x+) commend will cause the cutting tool to be located to the right of the last
point.
2. A “X minus” (x-) command will case the cutting tool to be located to the left of the last
point.
3. A “Y plus” (y+) command will cause the cutting tool to be located toward the column.+
4. A “Y minus” (y-) command will cause the cutting tool to be located away from the
column.
5. A “Z plus” (Z+) command will cause the cutting tool or spindle move up or away from the
work piece.
6. A “Z minus” (Z-) moves the cutting tool down or into the work piece. In incremental
programming, the G91 command indicates to the computer and MCU (Machine Control
Unit ) that programming is in the incremental mode.

Absolute program locations are always given from a single fixed zero or origin point
may be apposition on the machine table, such as the corner of the work table or at the any
specific point on the workpiece. In absolute dimension and programming, each point or
location on the workpiece is given as a certain distance from the zero or reference point.

Fig:5.12 : Example for Absolute system

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 1. A “X plus (X+) command will case the cutting tool be located to the right of the zero or
origin point.
2. A “X minus” (X-) command will cause the cutting tool to be located to the left of the zero
or origin point.
3. A “Y plus” (Y+) command will cause the cutting tool to be located to ward the column .
4. A “Y minus”(Y-) command will cause the cutting tool to be located away from the column.
In absolute programming, the G90 command indicates to the computer and MCU that the
programming is in the absolute mode.

5.20.8 Point To Point Continuous Path:

CNC programming falls into two distinct categories(fig. ) The difference between the
two categories was once very distinct. Now, however, most control units are able to handle
both point to point and continuous path machining. A knowledge of both programming
methods is necessary to understand what application search has in CNC.

CNC Positioning Systems

Point-to-Point (or) Positioning

Continuous path(or) contouring

Fig:5.13 : Point to point continuous path

5.20.9 Point To Point Positioning:
Point to Point positioning is used when it is necessary to accurately locate the
spindle, or the work piece mounted on the machine table, at one or more specific locations to
perform such operations as drilling, reaming, boring, tapping, and punching Point to Point
positioning is the process of positioning from one coordinate(XY) position or location to
another, performing the machining operation, and continuing this pattern until all the
operations have been completed at all programmed locations.

Fig:5.14 : Point to point positioning

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 In point 1 to point 2 is a straight line, and the machine moves only along the X axis, but
points 2 and 3 require that motion along both the X and Y axes takes place. As the distance in
the X direction is greater than in the Y direction, Y will reach its position first, leaving X to travel
in a straight line for the remain distance. A similar motion takes place between points3 and 4.

5.20.10 Continuous path Contouring:

Contouring, or continuous path machining, involves work such as that produced on a lathe
or milling machine, where the cutting tool is in contact with the workpiece as it travels from
one programmed point to the next continuous path positioning is the ability to control motions
on two or more machine axes simultaneously to keep a constant cutter workpiece relationship.
The programmed information in the CNC program must accurately position the cutting tool
from one point to the next and follow a predefined accurate path at a programmed feed rate in
order to produce the form or contour required.

Fig:5.15 : continuous path contouring

Fig: 5.16 : Tool path

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 5.20.11 Interpolation :
The method by which contouring machine tools move from one programmed point to the
next is called interpolation. This ability to merge individual axis points into a pre-defined tool
path is built into most of today’s MCUs. There are five methods of interpolation ,linear, circular,
helical, parabolic, and cubic. All contouring controls provide linear interpolation, and most
controls are capable of both linear and circular interpolation. Helical, parabolic, and cubic
interpolation are used by industries that manufacture parts which have complex shapes,such as
aerospace parts and dies for car bodies.

5.20.12 Linear Interpolation:

Liner interpolation consists of any programmed points linked to gather by straight lines,
whether the points are close together or far apart(Fig.11). Curves can be produced with linear
interpolation by breaking them into short, straight-line segments. This method has limitations,
because a very large number of points would have to be programmed to describe the curve in
order to produce a contour shape.
A contour programmed in linear interpolation requires the coordinates
positions (XY positions in two-axis work) for the start and finish of each line segment. Therefore,
the end point of one line or segment. Therefore, the end point of one line or segment becomes
the start point for the next segment, and so on, through out the entire program.

Fig:5.17 : Liner interpolation

5.20.13 Circular Interpolation :

The development of MCUs capable of circular interpolation has greatly simplified the
process of programming arcs and circles. To program an arc the MCU requires only the
coordinate positions(the XY axes) of the circle centre, the radius of the circle, the start point and
end point of the arc being cut, and the direction which the arc is to be cut (Clock wise or counter
clock wise) the information required may vary with different MCUs.

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 Fig:5.18: Circular interpolation
5.20.14 Programming Format:
Word addres in the most common programming format used for CNC programming
system. This format contains a large munber of different codes (preparatory and
miscellaneous) that transfer program information from the part print to machine
servos,relays,micro-switches,etc., to manufacture a part. These codes, which conform to EIA
(Electronic Industries Association) standards, are in a logical sequence called a block of
information. Each block should contain enough information to perform one machining
operation. Word address format every program for any part to be machined, must be put in a
format that the machine control unit can understand. The format used on any CNC machine
is built in by the machine tool bulider and is based on the type of control unit on the machine.
A variable-block format which uses words(letter) is most commonly used. Each instuction
word consists of an address character, such as X,Y,Z,G,M or S. Numerical data follows this
address character to identify a specific functions such as the distance, feed rate, or speed value.
The address code G90 in a program, tell the control that all measurements are in the absolute
mode. The code G91, tell the control that measurement are in the incremental mode.

5.20.15 Codes :
The most common codes used when programming CNC machine tools are G-codes
(preparatory functions) and M codes (miscellaneous functions ). Other codes such as F,S,D,
and T are used for machine functions such as feed, speed, cutter diameter offset, tool
number,etc. G-codes are sometimes called cycle codes because they refer to some action
ocurring on the X,Y,and /or Z axis of a machine tool,the G-codes are grouped into categories
such as group 01, containing codes G00, G01, G02, G03. Which cause some movement of the
machine table or head. Group 03 includes either absolute or incremental programming, while
Group 09 deals with canned cycles. A G00 code rapidly positions the cutting tool while it is
above the workpiece from one point to another point on a job. During the rapid traverse
movement, either the X or Y axis can be moved individually or both axes can be moved at the
same time. Althrought the rate of rapid travel varies from machine to machine ,it ranges
between 200 and 800in/min (5 and 20 m/min).

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 The G01,G02 and G03 codes move the axes at a controlled feedrate.
• G01 is used for stright-line movement (linear interpolation).
• G02 (clock wise) and G03(counter clock wise) are used for arcs and circle (circular
interpolation).

5.20.16 Programming for Positioning :

Before starting to program a job, it is important to become familiar the part to be
produced. From the engineering drawings, the programmer should be capable of planning the
machining sequences required to produce the part. Visual concepts must beput into a written
manuscript as the first step in developing a part program, it is the part program that will be
sent to the machine control unit by the computer, tape, diskette, or other input media. The
prodrammer must first establish a reference point for aligning the workpiece and the machine
tool for programming purposes. The manuscript must include this along with the type of
cutting tools and work-holding devices required, and where they are to be located.

5.20.17 Dimensioning Guidelines:

The system of rectangular coordinates is very important to the successful operation of
CNC machines. Certain guidelines should be observed when dimensioning parts for CNC
machining. The following guidelines will insure that the dimensioning languagemeans
exactly the same thing to the design engineer, the technician, the programmer, and the
machine operator.

1. Define part surface from three perpendicular reference planes.

2. Establish reference planes along part surface which are parallel to the machine axes.
3. Dimension from a specific point on the part surface.
4. Dimension the part elearly so that its shape can be understood without making
mathemetical calculations or guesses.
5. Define the part so that a computer numerical control cutter path can be easily
programmed.

5.20.18 Work setting and offsets:

All CNC machine tools require some form of work setting,toolsetting,and offsrts
(compensation) to place the cutter and work in the proper relationship. Compensation allows
the programmer to make adjustment for unexpected tooling and setup conditions.

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 Fig:5.19 : Work setting and offsets

Fig:5.20 : Work setting movement

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 5.20.19 Work Coordinates :
In absolute positioning, work coordinates are generally set on one edge or corner of a
part and all programming is generally taken from this position. In fig. the part zero is used
for all positioning for hole locations 1,2 and 3 . In incremental positioning, the work
coordinates change because each location is the zero point for the move to the next location.
On some parts,it may be desirable to change from absolute to incremental, or viceverse, at
certain points in job. Inserting the G90 (absolute) or the G91 (incremental) command into the
program at the point where the change is to be made can do this.

5.21 CUTTER DIAMETER COMPENSIATION:

Cutter diameter compensation (CDC) changes a milling cutter’s programmed center
line path to compensate for small differences in cutter diameter. On most MCUs, it is effective
for most cuts made using either linear or circular interpolation in the X-Y axis, but does not
affect the programmed Z-axis moves. Usally compensation is in increments of 0.0001in. up
to +1.0000 in., and usually most controls have as many CDCs available as there are tool
pockets in the tool storage matrix.

5.21.1 Advantage of CDC :

1. Allows the use of cutters that have been sharpened to as maller diameter.
2. Permits the use of a large or smaller tool already in the machine’s storage matrix.
3. Allow backing the tool away when roughing cuts are required due to exessive materical
present.
4. Permits compensation for unexpected tool or part deflection, if the deflection is constant
throught the programmed path.

The basic reference point of the machine tool is never at the cutting edge of a milling
cutter,but at some point on its periphery. If a 1.000 in. diameter end mill is used to machine the
edges of a workpiece,the programmer would have to keep a 500 in. offset from the work surface
in order to cut the edges accurately, fig.00. the offset represents the distance from the centerline
of the cutter or machine spindle to the edge of the part.

When ever a parrt is being machined,the programmer must calculate an offset path,
which is usually half the cutter diameter. Modern MCUs,which have part surface
programming,automatically calculate center line offsets once the diameter of the cutter for each
operation is programmed.

Many MCUs have operator entry capabilities which can compensate for diffrences in
cutter diameters,therefore an oversize cutter, or one that has been sharpened,can be used as long
as the compensation value for over size or undersize cutter is entered.

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 5.22 PROGRAM – BH1

BH1 PROFILE CODE :

1.program for Rough turning
; % MPF 1550
; N0001 ( BH1-PASS-MID-ROUGHING )
; N0002 ( PSDNN-25 TOOL TYPE 9 )
; N0003 ( ONLY PASS ROUGHING )
N10 R0 =850, R11 = 240, R15 = 1200, R12 = 360
N20 G0 , G90, G53 X1980
N30 M20 T1 D1; ( PSDNN-25 TOOL TYPE 9 )
N40 S20 , M03
N50 G0, Z = R15 +20
N60 R1 = R15 – R11
N70 R2 = 277, R3 = 47, R13 =97, R6 = 2.4, R18 =8
N80 L190
N90 R1 = R1- R12
N100 L190
N110 R1 = R1- R12
N120 L190
N130 G00, G40, G53 X1980
N140 M02

2. program for full groove cutting :

; % MPF 1551
; N0001 ( BH1 LEFT/ RIGHT ROUGHING )
; N0020 ( FIX PRSCL 25 ON M21, T6 TYPE 9 )
; N0030 ( FIX PRSCR 25 ON M20, T5 TYPE 9 )
N10 R0 = 850, R11 = 240, R15 = 1200, R12 = 360
N20 G0, G90 , G95, G40, G53 X1980
N30 G54, M20 T5 D1; ( PRSCR 25 ON M20 T5 D1 TYPE 9 )
N40 S20 M03
N50 G0, Z = R15 +20
N60 X = R0 + 20
N70 Z = R15, F1
N80 R2 = 147 , R3 = 11.034, R13 = 99, R6= 12.5, R18= 10

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 N90 R1= R15-R11
N100 L191
N110 G00, G40, G53 X1980
N120 G54, M03, M21, T6 D1; ( FIX PRSCR 25 ON M21 T6 D1 TYPE 9)
N130 L192
N140 G00, G40, G53 X1980
N150 R1 = R1-R12
N160 G54 ,M03, M02, T5 D1 ;( FIX PRSCR 25 ON M20 T5 D1 TYPE9 )
N170 L191
N180 G00, G40 ,G53 X1980
N190 G54, M03 , M21, T6 D1; ( FIX PRSCL 25 ON M21 T6 D1 TYPE 9 )
N200 L192
N210 G00, G40, G53 X1980
N220 R1 = R1-R12
N230 G54, M03, M20, T5 D1; ( FIX PRSCR 25 ON M20 T5 D1 TYPE 9 )
N240 L191
N250 G00, G40, G53 X1980
N260 G54 , M03, M21, T6 D1; ( FIX PRSXCL 25 ON M21 T6 D1 TYPE 9)
. N270 L192
N280 G00, G40, G53 X1980
N290 M02
3. PROGRAM FOR FINAL FINISHING CUT :
;% MPF 10
; N0010 ( BH1 LEFT/ RIGHT FINISHING NOMINAL )
; N0020 ( FIX PRSCL 25 ON M 21 T6 D1 TYPE 4 )
; N0030 ( FIX PRSCR 25 ON M20 T5 D1 TYPE 3 )
N0050 G00, G53, G90 X1980
N0060 TRANS X0,Z0
N0070 L101
N0075 L102
N0080 TRANS X0, Z- 360
N0090 L101
N0095 L102
N0100 TRANS X0, Z-720
N0110 L101
N0115 L102
N0120 M02
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 5.23 Work piece befour Process:

Fig:5.21 : Work piece Before Process

5.23.1 Work Piece After Process :

Fig:5.22 : Work Piece After process

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 CHAPTER:6

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 MECHANISMS
Major mechanisms in CNC lathe machine in VSP:
6.1 Power drives:
• In machine tools, power is generally required for driving the main spindle, saddle and
carriage and to some auxiliary units.
• The motors used for CNC system are of two types
1. Electrical-stepper motor, servo electrical motor
2. Fluid – Hydraulic or Pneumatic
• In CNC, usually servo electrical drives are used. They exhibit favorable torque-speed
characteristics and are relatively inexpensive.

Servo motors:
• Servomotors are special electromechanical devices that produce precise degrees of
rotation. The servo motor is a DC or AC or brushless DC motor combined with a position
sensing device. Servomotors are also called control motors as they are involved in
controlling mechanical system.
• The servomotor are used in a closed-loop servo system as shown in fig. A reference input
is sent to the servo amplifier, which controls the speed of the servomotor.
• A feed back device is mounted on the machine, which is either an encoder or resolver.
This device changes mechanical motion into electrical signals and is used as a feedback.
This feed back is sent to the error detector, which compares the actual operation with that
of the reference input.
• If there is an error, that error is fed directly to the amplifier , which will be used to make
necessary corrections in control actions. In many servo systems, both velocity and position
are monitored. Servomotors provide accurate speed, torque, and have ability of direction
control.

comparator Amplifier Motor

Command
signal Drive Machine
from MCU component slide

position
comparison

Feedback signal
Nc
transducer

Fig: 6.1 : Feed back system

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 • D.C servomotor:
D.C operated servomotors are usually respond to error signal abruptly and accelerate
the load quickly. A DC servo motor is actually an assembly of four separate components,
namely:

1. DC motor
2. Gear assembly
3. Position-sensing device
4. Control circuit

• AC servomotor:
Magnetic force is generated by a permanent magnet and current which further produce
the torque. It has no brushes so there is little noise/vibration. This motor provide high
precision control with the help of high resolution encoder.
The stator is composed of a core and winding. The rotor part comprises of shaft, rotor
core and a permanent magnet. Digital encoder can be of optical or magnetic type. It gives
digital signals, which are in proportion of rotation of the shaft.

Fig: 6.2: Ac servomotor

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 Tail stock mechanism :

Fig: 6.3 : Tail stock mechanism

6.2 RACK &PINION MECHANISM:

Rack and pinion gears are used to convert rotation into linear motion. A perfect example of this is
the steering system on many cars. The steering wheel rotates a gear which engages the rack. As the
gear turns it slides the rack either to the right or left depending on which way you turn the wheel.
Rack and pinion gears also used in some scales to turn the dial then displays your weight.

Fig: 6.4 : Rack & Pinion Mechanism

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 6.3 BALL SCREW MECHANISM:
A ball screw is a mechanical linear actuator that translates rotational motion to linear motion
with little friction. A threaded shaft provides a helical raceway for ball bearings which act as a
precision screw. As well as being able to apply or withstand high thrust loads, they can do so with
minimum internal friction. They are made to close tolerance and are therefore suitable for use in
situations in which high precision in necessary. They ball assembly acts as the nut while the threaded
shaft is the screw. In contrast to conventional lead screws, ball screws tend to be rather bulky, due
to the need to have a mechanism to re-circulate the balls.
Another form of linear actuator based on a rotating rod is the thread less ball screw, a.k.a.
“rolling ring drive”. In this design, these (or more) rolling ring bearings are arranged symmetrically
in a housing surrounding a smooth (thread less) actuator rod or shaft. The bearings are set at an
angle to the rod, and this angle determines the direction and rate of linear motion per revolution of
the rod. An advantage of this design over the conventional balls crew or lead screw in the practical
elimination of backlash and loading caused by preload nuts.

Fig: 6.5 : Ball Screw Mechanism

6.4 WORM & WORM WHEEL MECHANISMS:

A worm drive is gear arrangement in which a worm (which is a gear in the form of a screw)
meshes with a worm gear (which is similar in appearance to a spur gear). The two elements are
also called the worm screw and worm wheel. The terminology is often confused by imprecise use
of the term worm gear to refer to the worm, the worm gear, or the worm drive as a unit. Like other
gear arrangements, a worm drive can reduce rotational speed or transmit higher torque. A worm
is an example of a screw, one of the six simple machines. One of the major advantages of worm
gear drive units are that they can transfer motion in 90 degrees.

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 Fig: 6.6 : Worm & Worm wheel mechanism

A gear designed using a worm and worm wheel is considerably smaller than one made from
plain spur gears, and has its drive axis at 90° to each other. With a single start worm, for each 360°
turn of the worm, the worm wheel advances only one tooth of the gear wheel. Therefore, regardless
of the worm’s size (sensible engineering limits notwithstanding), the gear ratio is the given a single
start worm, a 20 tooth worm wheel reduces the speed by the ratio of 20:1. With spur gears, a gear
of 12 teeth must match with a 240 tooth gear to achieve the same 20:1 ratio. Therefore, if the
diametrical pitch (DP) of each gear is the same, then, in arrangement is considerably smaller to
volume.

6.5 RECENT ADVANCEMENTS IN CNC MACHINES

6.5.1 CNC CUTTING TOOL NEW PRODUCT:

In the recent years, the CNC cutting tool material applications is on the basis of scientific
research and the results of the new products focus on in high speed, hard, dry fine (super fine) CNC
machining technology field. CNC cutting tool materials research and development of new products
gets rapid development and progress in the super hard materials (diamond surface modified coating
material) TIC base class.
CERMET, CBN, A1203, SI3N4 base class ceramic, W, co-like coating and fine particles
(ultrafine particles) cemented carbide substrate and go-glass containing powder metallurgy fields.

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 6.5.2 SUPER HARD MATERIAL FIELD OF CNC CUTTING TOOL:
Various CNC cutting tools of diamond types have rapidly been applied to the mechanical
machining industry of high hardness, high strength, difficult to process non-ferrous metals (alloys)
and non-ferrous metals, non-metallic composite material parts of high-speed and high-efficiency.
Its overview are described as follows; automotive, motorcycle industry, single crystal diamond
face milling, threading insert, boring tools, turning tools, reamers, composite hole machining CNC
tool are massively used in high strength, high hardness Si-Al alloy parts in automatic production
line, bamboo flooring, furniture industry, crystalline CVD thick film deposition of diamond
(composite chip) end mills, forming cutter, face milling and face milling type cutters. Are a large
number of applications automatic production line; aviation, aerospace, automotive, and electronics
and information technology industry, diamond CVD. Thin film coating of CNC cutting tool is used
in milling, turning, drilling, and fiber.
Metal layer in the high hardness of the composite bamboo flooring, furniture, windows and
doors and other parts plates, carbon fiber thermoplastic composite materials, magnesium alloy,
graphite, ceramics, and other components, to meet the requirements of high speed, high life and
dry machining techniques.

6.5.3 CNC CUTTING TOOL SYSTEM:

In recent year, trends that the “HSK” tool manufacturers in the international gradually
replace the developed systems of other types of cutting tools. The developed countries in Europe
follow Germany DIN69893-1 HSK tool system standard and international standardization
organizing committee set the ISO/DIS standard for its development HSK cutting tool system has
the features of dynamic. And static rigidity and high positioning good accuracy, it allows high
speed both are easy regulation bamboo mould tool management, and saves the overall tool cost,
and lower production cost.
Its first used in machining centers, CNC boring and milling machines, the
various lathes (turning centers), the grinding (grinding centers), CNC plane and CNC machining
automatically generated online gradually expended to use covers almost all cutting tool fields.

6.5.4 APPLICATIONS:
CNC machine is used
a. In the metal removal industry.
b. In the metal fabrication industry.
c. In the electrical discharge machining industry.
d. In the wood working industry.
e. Laser welding in automobile industry.

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 CHAPTER:7

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 MAINTENANCE

The various forms of maintenance and their relationship are represented as in fig.

Maintenance

Planned Unplanned
maintenance maintenance

Preventive Corrective Predictive Emergence

maintenance maintenance maintenance maintenance

Running Shutdown Scheduled Breakdown

maintenance maintenance maintenance maintenance

Fig: 7.1: Types of maintenance

Preventive maintenance is the routine inspection and service actives designed to

detect potential failure conditions and make major adjustments or repairs that will be help prevent
major operating problem where as, breakdown maintenance is the emergency repair and it involves
higher cost of facilities and equipment that have been used until they fail to operate.

An effective preventive maintenance program for equipment requires properly trained

personnel, regular inspection and service and should maintain regular records. It is planned in such
a way that it will not disturb the normal operations, hence no down time cost of equipment. Break
down maintenance stops the normal activities and the machine as well as the operators is rendered
ideal till the equipment is brought back to normal condition of working.

For proper operation and to maintain its accuracy for many years maintenance is must for
every machine like that CNC machines also required proper maintenance. Because of that cost and
capability to machine any type of contour without skill up to an accuracy of 1micron. Maintenance
must for these machines.
Generally we go for two types of maintenance.
1)Preventive maintenance
2)Break down maintenance..

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 7.1 PREVENTIVE MAINTENANCE:
Preventive maintenance is most important to CNC machines in order to prevent breakage and
spoilage of parts of the machine proper preventive maintenance avoids early change of parts i.e.,
gives more life with required accuracy. This maintenance with do in regular intervals.
In this type of maintenance on yearly schedule is prepared. This yearly schedule is further
divided into monthly schedule and quarterly schedule. In monthly schedule we will check for some
check points these all given below. The quarterly schedule will go for every 3 months in this
schedule also we go for some check lists. The monthly and quarterly checks light are given below.
We will check these points carefully ad we will take any preventive action if necessary.
Preventive Maintenance system:
The preventive maintenance policy is a system of planned and scheduled maintenance.
The basic principal involved in this system is “preventive is better than care”. Preventive
maintenance includes:
1. Proper identification of all items, their documentation and coding.
2. Inspection of plant and equipment at regular interval .
3. Proper cleaning, lubrication of equipment.
4. To upkeep the machine through minor repairs, major overhauls etc.
5. Failure analysis and planning for their elilmination.
Preventive versus Breakdown Maintenance:
Preventive maintenance is the routine inspection and service activities designed to
detect potential failure conditions and make major adjustments or repairs that will be help prevent
major operating problem where as the, breakdown maintenance is the emergency repair and it
involves higher cost of facilities and equipment that have been used until they fail to operate.

An effective preventive maintenance program for equipment require properly trained

personnel, regular inspection and service and should maintain regular records. It is planned is such
a way that it will not disturb the normal operations, hence no down time cost of equipment.
Breakdown maintenance stops the normal activities and the machine as well as the operators is
rendered ideal till the equipment is brought back to normal condition of working.

Total costs

costs
M Cost of preventive maintenance
- - - - - - - - - |-
|
|
| Cost of break down maintenance
|
|
|

Amount of maintenance activity

Fig: 7.2 : Graph of Preventive maintenance

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 7.1.1 PREVENTIVE MAINTENANCE CHECK LIST FOR CNC ROLL
TURNING LATHES FOR MONTHLY:
Head stock:
a. Check for oil level in head stock lubrication tank and refill if necessary.
b. Check for filter contamination.
c. Individual lubrication of clamping jaws.
d. Check centre surface condition and bolts tightness.
Oil cooler:
a. Clean the laminas of the condenser and filter.
Carriage:
a. Circulation of lubrication in carriage, check for oil level and refill it necessary.
b. Check filters contamination through electrical signals.
c. Check the turret head bolts.
Telescopic covers on carriage bed and cross feed:
a. Oil should be applied after cleaning in extended conditions.
Tail stock:
a. Dirt strippers in bed side, condition and exchange if necessary.
b. Tail stock rack cleaning and apply oil.
c. Central lubrication of tail stock guide ways tan.
d. Check oil level/pressure in clamping cylinders system.
e. Check for air ventilation in micro speed unit.
f. Check or leaks in micro speed unit.
g. Check center bolts tightness and surface condition.
h. Check for force measuring unit gauge.
General:
a. Check all pressure gauge and note the reading.
b. Check all pumps for vibration and high pump temperature, preventive maintenance check
list for CNC roll turning lathes.
7.1.2 PREVENTIVE MAINTENACE CHECK LIST FOR CNC ROLL
TURNING LATHES FOR QUARTERLY:
a. Remove telescopic cover on the carriage bed and on cross feed clean them with kerosene
and oil.
b. Check condition of bed slide and cross feed guide ways.
c. Check functions of turret and tightness of bases bolts.
d. Check function of load cell in tail stock and refill with working substance if necessary.
e. Check guide black flash readjust the conical jibs if necessary.
f. Record hydro static pocket pressure in ‘Z’ & ‘X’ axis. Control pocket pressure if required.
g. Check run out for centers and record for head and tail stock.
The intervals given for the performance of maintenance works are based on normal working
conditions. The actual operating conditions may however require that alternation is made to the
maintenance schedule maintenance must be carried out at shorter intervals if the machine is
operated in dirty and dusty surrounding.

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 The frequency of inspection depends on the quality the foundation, the degree of loading and the
machining accuracy required. Irregularities and faults must be taken care of at one.

7.1.3 MAINTENANCE PLANE:

Table:2
Number of component Operating hours Work to be carried out
1. General
1.1 Electrical 200 Check condition and fixing of all
cables switches, cable terminals and
contacts.
600 Check functions and fixing of all limit
switches.
1.2 Hydrostatics, hydraulics 1500 Check functions of all pneumatic
pumps and supply of hydrostatics
units.
2. Lubrication
2.1 Lubrication instruction All necessary oil filtering measures
are to be carried out in with
lubrication instruction.
2.2 Oil-recoiling device 200 Check contamination of filter mat
clean upon dark colouring
Lamellas 200 Check contamination of lamellas of
air cooled condensate.
3. Machine bed
3.1 Telescoping cover o the carriage bed 200 Clean in extended condition.
600 Remove cover and clean. Then spray
with oil.
3.2 Guide ways 600 Check condition
4. Head stock
4.1 Disk break 200 Check air filters, clean if necessary.
4.2 D.C motor 1000 Check carbon brushes replace if
necessary.
5. Tail stock
5.1 Dirt wiper 200 Check condition of wiper of ring at
the quill, replace if necessary.
5.2 Force measurement working 1500 Check functions, refill unit with
substance if necessary.
5.3 Conical gibes 1500 Check guide backlash, readjust if
necessary.
5.4 Fine feed drive 1500 Determine displacement path of the
break at control window.

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 7.1.4 LUBRICATION INSTRUCTIONS:
Table :3
Lubrication Machine part Remarks
point

.Item No
K1 1 Circulation lubrication: Head stock, rolling Check oil level, refill if necessary.
bearing, gear wheels

1 1 Hydraulics step switching First oil change pump off oil, clean
tank and refill with oil.

F1 1 Pressure filter at oil tank Exchange filter insert when message

given.

2 1 Individual lubrication: Adjustment elements Clean elements and re-grease.

and slide ways of clamping jaws

3 1 Individual lubrication: Rack of tail stock Clean and re-grease racks.

adjustment

4 2 Individual lubrication: Centre shaft bearing Grease nipple with grease gum 3-4
front and rear strokes.

K5 1 Hydraulics: Tail stock clamping Check oil level and refill.

K6 1 Central lubrication: Tail stock and gear Check oil level and refill.

7 - Individual lubrication: Roller bearings in Change grease. Remove bearing and

gears for centre shaft adjustment rinse out.

8 - Individual lubrication: Drive motor Grease nipple with grease gun.

9 - Individual lubrication Lifetime lubrication fill up resp.
change grease at dissembling due to a
fault or general overhaul.

10 1 Filter plates at oil tank Clean filter plates when message

given.

11 1 Pressure filter at oil tank Exchange filter insert when message

given.

12 1 Gear-box of X-axis At oil change let oil also of gear box

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 7.1.5 HYDROSTATIC OIL TANK:
The hydrostatic system of the machines are supplied with oil from the tank situated in the
foundation. To guarantee trouble free functioning of the unit, it is necessary to ensure that only
clean oil is conveyed to the hydrostatic guide ways. For this purpose, the tank is designed
according to the three chamber system.
The oil flowing back from the machine is pre purified in the first chamber by permanently
magnetic filter bars and a strainer basket for fine filtering, the oil it strained from beneath through
edge filters in the bottom instead of being pressed into the filter.
The thread chamber is the useful chamber proper of the tank, from which the oil pumped
through a low pressure super fine filter to the consuming points.

Fig:7.3: Hydrostatic Oil Tank

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 CHAPTER:8

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 Estimation and costing

8.1BH1 Roller manufacturing cost:

Roller weight in tons = 5.345 tons
Diameter of cylinder = ∅850 mm
Length of the cylinder = 1200 mm
Volume of cylinder(V) = 𝜋r2h
= 𝜋 × (42.5)^2 × 120
= 680940.20 cm3
Density of alloy forged steel = 7.85 g/cm3
Alloy forged steel cost per kg = 125 Rs/kg
Total cost of roller = 5345 × 125
= 6,68,125 Rs

Life time of each roller = 5,25,000 tons

Roll shop production rate per hr = 480 tons/hr
number of roller required for 1 year = 4 (as per the previous year2018 )
Net power required to machine(p) = 32.756 kw
Machining time required(T) = 50 min
Shipping cost/ each roller = 5000 Rs
Transportation cost = 3000 Rs
machine operator allowance = 2.63 Rs/min
power cost of 1 watt = 2 Rs
total power cost = 2×32756
= 65512 Rs

Total cost to manufacture BH1 roller = total cost of roller+ power cost+ shipping cost
+ Transportation cost + allowance
= 6,68,125 + 65,512 + 5000 +3000+ 110
= 7,38,747 Rs
Roller cost for year = 738747× 4
= 2954988 Rs / year

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 8.2 BV3 Roller manufacturing cost:
Roller weight in tons = 3.285 tons
Diameter of cylinder = ∅730 mm
Length of the cylinder = 1000 mm
Volume of cylinder(V) = 𝜋r2h
= 𝜋 × (36.5)^2 × 100
= 418538.68 cm3
Density of alloy forged steel = 7.85 g/cm3
Alloy forged steel cost per kg = 125 Rs/kg
Total cost of roller = 3285 × 125
= 4,10,625 Rs

Life time of each roller = 5,25,000 tons

Roll shop production rate per hr = 480 tons/hr
number of roller required for 1 year = 4 (as per the previous year2018 )
Net power required to machine(p) = 28.131 kw
Machining time required(T) = 41.66 min
Shipping cost/ each roller = 5000 Rs
Transportation cost = 3000 Rs
machine operator allowance = 2.63 Rs/min
power cost of 1 watt = 2 Rs
total power cost = 2×28131
= 56262 Rs

Total cost to manufacture BV3 roller = total cost of roller+ power cost+ shipping cost
+ Transportation cost + allowance
= 4,10,625 + 56262 + 5000 +3000+ 110
= 4,74,997 Rs
Roller cost for year = 4,74,997 × 4
= 1899988 Rs

The cost saved by our project = 2954988 – 1899988

= 10,55,000 Rs
The project save 10,55,000 Rs for 1 year. Monthly 87,917 Rs will saved .

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 CHAPTER:9

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 9.CONCLUSION :

If we replace BH1 roller with the BV3 roller ,we can reduce the maintenance
cost and sudden break down of work , during failure of the roller . This will also increase the
effectiveness of rolling mill in RS& RS Department. The power consumption is reduced.
The working time of CNC lathe machine is also increased .

DEPARTMENT OF MECHANICAL ENGINNERING ,VISIT COLLEGE Page | 92

 9.1 Reference:
1. A Text Book Of Production Technology by Dr. P.C Sharma
2. A Text book of Machine Design by R.S KURMI.
Journals:
1. Computer-aided roll pass design for continuous billet mill , ASHOK KUMAR,
SUDHAKER JHA and V RAMASWAMY Research & Development centre for
Iron and Steel, Steel Authority of India Limited, Ranchi, India.
2. Cutting Forces in Turning Operations, Sergi Martín Umbert ,Mechanical
engineer , Norwegain University of Science and Technology.
3. Machine Maintenance Scheduling with Reliability Engineering Method and
Maintenance Value Stream Mapping, N Sembiring* and A H Nasution
Departemen Teknik Industri, Fakultas Teknik, Universitas Sumatera Utara,
Jalan Almamater Kampus, Medan 20155
4. IJSRD - International Journal for Scientific Research & Development| Vol. 4,
Issue 02, 2016 | ISSN (online): 2321-0613

5. International Journal of Advanced Scientific Research ISSN: 2456-0421

www.newresearchjournal.com/scientific Volume 1; Issue 1; April 2016; Page
No. 13-17

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