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CNC Machine, Johor Bahru (2025)

28/07/2025

Here's a breakdown of each point:

* - Miscellaneous function: M codes are generally used for miscellaneous functions or functions related to machine operations that do not directly control tool movement.

* - Machine operations related functions: This reiterates that M codes pertain to various operational functions of the machine.

* M01 – Optional stop: Acts as an optional program stop. The machine will pause if the "optional stop" function is activated on the control panel.

* M02 – Program stop: Halts the program completely after all operations are finished, but does not reset the program to the beginning.

* M03 – Spindle on, CW: Turns the spindle (the component that rotates the tool or workpiece) on in a clockwise direction.

* M04 – Spindle on, CCW: Turns the spindle on in a counter-clockwise direction.

* M05 – Spindle stop: Stops the rotation of the spindle.

* M06 – Turret indexing: Instructs the machine to perform a tool change or index the turret (the part that holds multiple tools) to the next tool position.

* M07 – Coolant on: Turns on the coolant system, typically to lubricate and cool the tool and workpiece during the machining process.

* M08 – Coolant on: Similar to M07, also for turning on the coolant system. Sometimes there are two M codes for coolant on if there are two different channels or types of coolant, or this might simply be a duplication.

* M09 – Coolant off: Turns off the coolant system.

* M30 – Program stop and rewind: Stops the program and resets it to the beginning (rewind), making it ready to be run again from the start. This is often used at the end of a machining cycle.

In summary, this image serves as a concise guide to the most common M codes used in CNC programming to control non-motion functions on a machine.

28/07/2025

This image is a presentation slide displaying two formulas for calculating "Spindle Speeds," often denoted by 'N'. Spindle speed refers to the number of revolutions per minute (RPM) that a spindle on a machine tool performs.
The two formulas shown are:

* N = \frac{V \times 1000}{\pi D}
* N = \frac{V \times 12}{\pi D}
Let's explain each variable and the difference between the two formulas:

* N: Spindle Speed (typically in revolutions per minute or RPM).
* V: Cutting Speed. This is the relative speed between the cutting tool and the workpiece.

* In the first formula, 'V' is likely in meters per minute (m/min), as it's multiplied by 1000 to convert meters to millimeters, which is consistent with 'D' if 'D' is in millimeters.

* In the second formula, 'V' is likely in feet per minute (FPM), as it's multiplied by 12 to convert feet to inches, which is consistent with 'D' if 'D' is in inches.

* \pi (Pi): A mathematical constant, approximately 3.14159.

* D: Diameter of the workpiece or the cutting tool (depending on the machining application, e.g., rotating workpiece or rotating tool).

* In the first formula, 'D' is likely in millimeters (mm).

* In the second formula, 'D' is likely in inches (in).

The main difference between these two formulas lies in the unit system used:

* First formula (N = \frac{V \times 1000}{\pi D}): This formula is commonly used in the metric system. 'V' is the cutting speed in meters per minute (m/min), and 'D' is the diameter in millimeters (mm). The factor of 1000 is used to convert meters to millimeters to ensure consistent units for diameter and circumference.

* Second formula (N = \frac{V \times 12}{\pi D}): This formula is commonly used in the imperial system (United States). 'V' is the cutting speed in feet per minute (FPM), and 'D' is the diameter in inches (in). The factor of 12 is used to convert feet to inches to ensure consistent units for diameter and circumference.

Overall, this image explains how to calculate the optimal spindle speed for machining operations, by providing different formulas for both metric and imperial measurement systems. Selecting the correct formula is crucial for ensuring calculation accuracy and machining process efficiency.

28/07/2025

This image displays "Cutting Speed Charts," specifically for milling operations using carbide as the cutting tool material.

This chart provides recommended cutting speeds for various material types, presented in two units of measurement:

* Meters per min (MPM)
* Surface feet per min (SFM)
For each material type, three values are given:
* Min (Minimum): The lowest recommended cutting speed.
* Median: The average or common recommended cutting speed.
* Max (Maximum): The highest recommended cutting speed.

The material types listed in this chart are:

* Stainless Steel
* Alloy Steel
* Low Carbon Steel
* Free Cutting Steels
* Brass & Bronzes
* Aluminium
* Cast Iron

Charts like this are crucial in the manufacturing and machining industry as they help operators and engineers select the optimal cutting speed to achieve efficiency, good surface finish, and extended tool life when performing milling operations with carbide tools. Incorrect speed selection can lead to rapid tool wear, poor surface quality, or even damage to the workpiece or machine.

28/07/2025

This image is a table of UNF Tapping Drill Sizes, which shows the appropriate drill bit sizes for creating internal threads (tapping) based on the UNF (Unified National Fine) thread standard. The table includes three main columns:

1. Size – Indicates the nominal size of the thread, measured in inches.

2. Pitch (tpi) – Refers to the number of threads per inch. A higher TPI means the threads are finer and closer together.

3. Drill (mm) – Specifies the drill bit diameter in millimeters (mm) that should be used before tapping, to ensure the resulting thread matches the UNF standard.

For example:

To create a UNF thread with a 1/2 inch size and 20 TPI, a 11.5 mm drill bit is required.

For a 1 1/2 inch thread size with 12 TPI, a 36 mm drill bit should be used.

This table is essential in machining and metal fabrication to ensure that internal threads are made accurately, with proper strength and precision.

27/07/2025

British Standard Whitworth (BSW) thread chart with a 55° thread angle. The chart provides essential information for drilling and tapping operations using BSW standard bolts and taps.

Column Explanation:

1. Bolt/Tap Size: The nominal diameter of the bolt or tap (in inches), such as 3/32 BSW, 1/4 BSW, up to 2 BSW.

2. Teeth Per Inch (TPI): The number of threads per inch. A higher number means finer threads.

3. Tapping Drill Size: The recommended drill size for tapping, shown in both inches and millimeters. This is the size of the hole to drill before cutting the threads.

Example:

1/4 BSW has:

20 TPI

Tapping Drill Size: 13/64" (5.1mm)
This means to create a 1/4 BSW internal thread, you should drill a 5.1mm hole before tapping.

Purpose of the Chart:

This chart is especially useful for machinists, lathe operators, and engineers, helping them select the correct drill size before tapping to ensure the threads are accurate, durable, and to avoid stripping or excessive wear.

27/07/2025

💡 CNC Lathe Program Example – Fanuc G34 (Variable Lead Thread)

%
O1001 (VARIABLE LEAD THREAD - FANUC LATHE)

G21 G40 G99 G97 (MM MODE, CANCEL TOOL RADIUS COMP, FEED PER REV, CANCEL CSS)
T0101 (TOOL 1, OFFSET 1)
M03 S600 (SPINDLE ON CLOCKWISE, 600 RPM)
G00 X20.0 Z5.0 (RAPID POSITIONING TO START POINT)

G34 Z-50.0 F2.0 K0.05 (VARIABLE LEAD THREADING:
START LEAD 2.0 MM/REV,
INCREASE BY 0.05 MM/REV PER REVOLUTION)

G00 X100.0 Z100.0 (RAPID MOVE AWAY)
M05 (SPINDLE STOP)
M30 (END OF PROGRAM)
%

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📘 Program Explanation:

Line Description

O1001 Program number
G21 Programming in millimeters
G99 Feed per revolution mode (required for threading)
G97 Cancels CSS mode, uses constant RPM
T0101 Selects tool 1 with offset 1
M03 S600 Spindle ON clockwise at 600 RPM
G00 X20.0 Z5.0 Rapid move to the starting position of the thread
G34 Z-50.0 F2.0 K0.05 Executes variable-lead threading: Starts with 2.0 mm/rev and increases 0.05 mm/rev per spindle revolution until Z = -50.0
G00 X100 Z100 Rapid move away from the part
M05, M30 Spindle stop and end of program

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⚠️ Notes:

Use a threading insert and holder suitable for the thread profile.

G95 or G99 (feed per rev) must be active for accurate threading.

G34 is only available on machines that support variable-lead threading.

For multi-pass threading, consider using G76 or a looped G34 with depth control.

27/07/2025

The biggest difference between a conventional manual lathe and a modern CNC (Computer Numerical Control) lathe lies in their method of control and level of automation. Here's a breakdown of the key differences:

1. Control and Operation:
* Conventional Manual Lathe: Operated manually by a skilled machinist. The operator directly controls the movement of the cutting tools using handwheels and levers, constantly adjusting speeds, feeds, and cutting depths. It requires continuous human intervention and a high degree of skill and experience.

* CNC Lathe: Controlled by a computer program. The machinist inputs G-code and M-code commands (or uses CAD/CAM software to generate them) that tell the machine exactly how to move, what speed to use, and where to cut. Once programmed, the machine operates automatically with minimal human supervision.

2. Precision and Accuracy:
* Conventional Manual Lathe: Precision heavily relies on the operator's skill, experience, and attention to detail. While high precision can be achieved, it's more susceptible to human error and variations between parts.

* CNC Lathe: Offers significantly higher and more consistent precision and accuracy. The computer control eliminates human error in movement, allowing for extremely tight tolerances (often down to 0.001mm or less) and highly repeatable results, making every part virtually identical.

3. Repeatability and Production Volume:
* Conventional Manual Lathe: Ideal for one-off parts, custom jobs, or small batches where flexibility and hands-on control are valued. Reproducing identical parts consistently can be challenging and time-consuming.

* CNC Lathe: Excellently suited for mass production of identical parts. Once a program is set, it can run continuously, producing large quantities with consistent quality and high efficiency.

4. Complexity of Parts:
* Conventional Manual Lathe: Limited in the complexity of shapes and features it can produce efficiently. Complex contours, intricate threading, or non-linear movements can be very difficult or impossible to achieve manually.

* CNC Lathe: Can create highly complex geometries, intricate designs, and multi-axis contours with ease, thanks to its programmed movements and ability to handle multiple axes simultaneously.

5. Speed and Efficiency:
* Conventional Manual Lathe: Slower overall due to manual operations, setup changes, and the need for constant monitoring.
* CNC Lathe: Much faster and more efficient. Reduced setup times, automated tool changes, and continuous operation lead to significantly higher production speeds and throughput.

6. Skill Requirements:
* Conventional Manual Lathe: Requires highly skilled and experienced machinists who understand mechanics, material properties, and have excellent manual dexterity.

* CNC Lathe: Requires skills in programming, CAD/CAM software, and machine operation/supervision. While still requiring knowledge, the manual dexterity aspect is greatly reduced.

7. Cost:
* Conventional Manual Lathe: Generally has a lower initial investment cost, making it more accessible for small workshops or hobbyists.
* CNC Lathe: Higher initial investment cost due to the complex electronics, software, and mechanical components. However, the long-term return on investment (ROI) can be higher due to increased efficiency, reduced labor costs, and less material waste.

8. Safety:
* Conventional Manual Lathe: Operators are in closer proximity to moving parts and cutting tools, potentially posing higher safety risks if proper procedures are not followed.
* CNC Lathe: Often features enclosed work areas and automated operations, which can enhance operator safety by reducing direct interaction with moving components during machining.

In summary, while both types of lathes perform the fundamental task of removing material from a rotating workpiece, the CNC lathe leverages computer automation to achieve superior precision, repeatability, speed, and the ability to produce complex parts, making it the preferred choice for modern manufacturing and high-volume production. Conventional manual lathes still hold value for custom work, repairs, training, and situations where hands-on flexibility is prioritized.

27/07/2025

Here's an explanation for each operation shown:

* Facing:
* The process of cutting the end surface of a workpiece to make it flat and perpendicular to the axis of rotation. The cutting tool moves traversely across the surface of the workpiece.

* Taper Turning:
* The process of producing a conical (tapered) surface on a workpiece. This can be done by feeding the tool at an angle relative to the axis of rotation.

* Contour Turning:
* The process of creating non-linear or curved shapes on a workpiece. The cutting tool follows a complex path to produce the desired profile.

* Forming:
* Uses a specialized tool that has the desired profile shape. This tool is plunged directly into the workpiece to transfer its shape onto the workpiece surface.

* Boring:
* The process of enlarging or refining an existing hole in a workpiece. A boring bar is inserted into the hole and removes material from the inside.

* Chamfering:
* Creating a sloped or beveled edge at the corner of a workpiece. This is typically done to remove sharp edges or for aesthetic/functional purposes.

* Parting Off:
* Cutting a section off the workpiece being machined. A parting-off tool is a narrow tool that is plunged into the workpiece until it separates.

* Threading:
* Creating external or internal screw threads on a workpiece. A special threading tool is used, moving axially at a specific feed rate in coordination with the workpiece's rotation to create the desired thread profile.

* Drilling:
* Creating a new hole in a workpiece. A drill bit is held in the tailstock of the lathe and fed into the rotating workpiece.

* Knurling:
* Creating a textured pattern (usually a diamond pattern) on the surface of a workpiece. This is done to improve grip, for example, on tool handles or k***s. A knurling tool has rollers that are pressed against the workpiece surface.

Overall, this image is an excellent illustration for understanding the fundamental operations that can be performed on a lathe, showcasing the versatility and capabilities of this machine in manufacturing processes.

27/07/2025

Why is a micrometer made of invar steel?

Invar is a metal alloy (typically 64% iron and 36% nickel) known for having a very low coefficient of thermal expansion, meaning its size changes very little with temperature variations.

➡️ Main reasons for using invar in micrometers:

High accuracy: Since invar doesn't expand or shrink significantly due to temperature changes, it ensures stable and precise measurements even in varying environments.

Dimensional consistency: Critical parts like the spindle and anvil must maintain consistent dimensions to avoid measurement errors. Invar is ideal for this purpose.

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Why is the U-shaped frame made of cast iron?

The U-shaped frame is the main structure of a micrometer that holds the measuring components in place.

➡️ Reasons for using cast iron in the micrometer frame:

Strong and rigid: Cast iron has excellent rigidity, so the frame does not bend or deform easily during use.

Resistant to vibration and pressure: This is important to avoid any impact on measurement accuracy when clamping the micrometer onto a workpiece.

Low cost and easy to mold: Cast iron is relatively inexpensive and can be cast into the U-shape with high precision.

Durable: It is long-lasting and resistant to wear.

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Conclusion:

Invar is used for precise measurement due to its thermal stability.

Cast iron is used for the frame due to its strength, rigidity, and mechanical stability.

27/07/2025

Here's an explanation for each type shown:

* Outside Micrometer: This is the most common type of micrometer. It is used to measure the external (outer) dimensions of an object, such as plate thickness or cylinder diameter.

* Digimatic Micrometer: This is essentially an outside micrometer, but it is equipped with a digital display for reading measurements. This makes it easier and faster to read results compared to traditional analog micrometers which require scale reading.

* Screw Thread Micrometer: This micrometer is specifically designed to measure the pitch diameter of screw threads. Its anvil and spindle have special shapes (typically conical and V-shaped) to fit into the thread grooves.

* Disk Micrometer: This micrometer has disk-shaped (or disc-shaped) anvil and spindle. This design allows for the measurement of thin workpieces, such as paper, sheet metal, or flanges, where regular anvils and spindles might be too thick.

* Point Micrometer: This micrometer features pointed anvil and spindle. It is used to measure the dimensions of small features or in hard-to-reach places, such as narrow grooves, recesses, or thin pipe wall thicknesses.

* Spline Micrometer: This micrometer is designed to measure the diameter of spline grooves or other parts with multiple parallel grooves. Its anvil and spindle are typically narrower or have a specific shape to fit into spline grooves.

Overall, this image serves as an excellent visual guide for recognizing various types of micrometers and their specific applications in the field of precision measurement.

26/07/2025

Explanation of the Elements in the Image:

At the center, there is the CNC command G34, which is used to create a thread with a variable lead.

The format of the command is:

G34 Z F K ;

Here's what each parameter means:

Z = The end position of the thread (along the Z-axis).

F = The initial lead, representing the axial distance the tool travels per spindle revolution.

K = The increment of lead per revolution, which causes the lead to gradually change from the starting value to the final value.

Example Applications:

Variable-lead threads are used in:

Mechanisms that require gradual acceleration or pressure adjustment.

Screw conveyors where material flow rate needs to vary.

High-precision actuator components.

Visual Description:

In the image, you can see that the spacing between the thread peaks increases from left to right, indicating a progressive increase in lead — the result of a positive K value.

26/07/2025

Here’s a breakdown of the command format G85 X Y Z R F:

G85: The command code to start the boring cycle with feed-in and feed-out motion (no rapid retract).

X: X-axis coordinate of the hole (optional).

Y: Y-axis coordinate of the hole (optional).

Z: The depth of the hole to be machined.

R: Retract level, the position the tool moves to before and after boring.

F: Feedrate, which determines the speed of the tool’s movement during the boring operation.

Characteristics of the G85 Cycle:

The tool feeds down into the hole at the specified feedrate.

Once the tool reaches the Z-depth, it retracts back to the R-level at the same feedrate, not at rapid speed.

This cycle is ideal for finishing operations, as the smooth feed-in and feed-out motion helps avoid scratching the hole’s surface.

The image also shows an illustration of the boring tool moving vertically into the workpiece, representing the boring process.

CNC Machine

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