Table of Contents

1 Title ....................................................................................................................................................... 5
2 Objectives.............................................................................................................................................. 5
3 Conventional Machining ....................................................................................................................... 5
3.1 Working Principle of Conventional milling machine ..................................................................... 5
4 CNC ........................................................................................................................................................ 6
5 CNC Machining ...................................................................................................................................... 6
5.1 Working principle of CNC milling machine ................................................................................... 6
6 Milling Machine .................................................................................................................................... 7
6.1 Types of Milling Machine .............................................................................................................. 7
6.1.1 Knee Type Milling Machine ................................................................................................... 7
6.1.2 Ram Type Milling Machine.................................................................................................... 7
6.1.3 Bed Type Milling Machine..................................................................................................... 7
6.1.4 Planer Type Milling Machine................................................................................................. 7
6.1.5 Horizontal Milling Machine ................................................................................................... 7
6.1.6 Vertical Milling Machine ....................................................................................................... 8
7 Parts of Vertical Milling Machine: ......................................................................................................... 8
7.1 Base ............................................................................................................................................... 8
7.2 Over Arm ....................................................................................................................................... 8
7.3 Knee .............................................................................................................................................. 8
7.4 Table.............................................................................................................................................. 8
7.5 Vertical Head ................................................................................................................................. 8
7.6 Spindle........................................................................................................................................... 8
7.7 Ram ............................................................................................................................................... 8
8 Milling Operations................................................................................................................................. 8
Face Milling ............................................................................................................................................... 8
8.1 Plain Milling................................................................................................................................... 9
8.2 Straddle Milling ............................................................................................................................. 9
8.3 Angular Milling .............................................................................................................................. 9
8.4 Form Milling .................................................................................................................................. 9
8.5 End Milling .................................................................................................................................... 9
8.6 Gear Milling ................................................................................................................................... 9
8.7 Helical Milling ................................................................................................................................ 9

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 8.8 Cam Milling ................................................................................................................................... 9
8.9 Thread Milling ............................................................................................................................... 9
9 Advantages of Milling Machine ............................................................................................................ 9
10 Disadvantages of Milling Machine .................................................................................................. 10
11 Advantages of CNC Milling Machine ............................................................................................... 10
12 Disadvantages of CNC Milling Machine .......................................................................................... 10
13 BEST METHOD FOR MILLING........................................................................................................... 10
14 PRODUCT CHOSEN AND ITS MATERIAL .......................................................................................... 10
14.1 BASIC PROPERTIES ...................................................................................................................... 11
14.1.1 Chemical Composition ........................................................................................................ 11
14.2 6061-T6 ....................................................................................................................................... 11
14.3 MATERIAL FOR MANUFACTURING DESIRED PART ..................................................................... 11
15 2D VIEWS OF DESIRED PRODUCT.................................................................................................... 13
15.1 FRONT VIEW................................................................................................................................ 13
15.2 SIDE VIEW.................................................................................................................................... 13
16 3D MODEL OF DESIRED PRODUCT .................................................................................................. 13
17 Programming codes used in CNC milling ........................................................................................ 14
18 Comparison ..................................................................................................................................... 15
19 Completion of product on milling machine .................................................................................... 16
20 Completion of product on CNC milling machine ............................................................................ 16
21 Results ............................................................................................................................................. 16
22 Conclusion ....................................................................................................................................... 16
23 References ...................................................................................................................................... 17

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Table of Figures
Figure 1 Conventional Milling Machine ....................................................................................................... 5
Figure 2 Working Principle ......................................................................................................................... 6
Figure 3 CNC Machine ................................................................................................................................ 6
Figure 4 Material for manufacturing........................................................................................................... 11
Figure 5 Front view..................................................................................................................................... 13
Figure 6 Side View ..................................................................................................................................... 13
Figure 7 3D Model ...................................................................................................................................... 13

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Abstract
The manifesto of this report is to compare the part manufacturing by CNC and conventional
milling machine. For this purpose, the connecting rod is manufactured on both machines. The part
manufactured on the milling machine was very time consuming and it includes several steps. Each
step is to be performed accurately and precisely. While on the other hand, the manufacturing of
the part on CNC was quite easy and simple. It does not include many steps. Only a program code
is developed which is fed to the machine and it manufactures the part automatically. A connecting
rod provides support to the workpiece and is used in milling operations. It is of great importance
and hence cannot be neglected in any way.

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1 Title
To produce a prismatic workpiece of steel with fixed cutting conditions and specified tolerance
using both conventional and CNC milling machines.

2 Objectives
Following are the main objectives of this report:
• Manufacturing of connecting rod by conventional milling machine and CNC
• To check the dimensional accuracy of parts made by conventional milling machine and
CNC

3 Conventional Machining
The conventional machining process uses a human operator to direct and control machining tools
such as milling, boring, and drilling machines as well as millings and other sharp cutting tools.
This individual is responsible for driving the location and intensity of tool contact with the raw
material through the use of buttons, levers, or wheels in order to achieve the intended product
geometry [1].

Figure 1 Conventional Milling Machine [2]

3.1 Working Principle of Conventional milling machine

• The workpiece is holding on the worktable of the machine.

• The table movement controls the feed of workpiece against the rotating cutter.

• The cutter is mounted on a spindle or arbor and revolves at high speed.

• Except for rotation the cutter has no other motion.

• As the workpiece advances, the cutter teeth remove the metal from the surface of workpiece
and the desired shape is produced [3].

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 Figure 2 Working Principle [4]

4 CNC
Computerized Numerical Control. In modern CNC Technology, the MCU consists of a
microcomputer and control hardware that stores the program of commands and executes it by
converting each instruction into mechanical actions of machine tool i.e. one command at a time

5 CNC Machining
Although CNC machining still requires operator oversight to manage software, functions in the
CNC process are primarily carried out by pre-programmed computer designations that guide the
movements of the machining tools. Tools used in the CNC process do not require contact with the
raw materials [5].

Figure 3 CNC Machine [6]

5.1 Working principle of CNC milling machine

• In a CNC system, a dedicated computer is used to perform all the essential functions as per
the executive program stored in the computer memory.
• The system directs commands to servo drives to drive the servo motor & other output
devices like relays, solenoids, etc.
• To initiate the operations such as motor starting & stopping, coolant on & off, tool
changing, pallet changing, etc., and other miscellaneous functions.

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 • The movement of X, Y, Z axis are controlled by a motor which supplies either alternating
current or Direct current.
• The movement of the machine is done by giving commands.
• All the operations are carried out by codes like speed, feed, depth of cut, etc.
• For each operation separate code is available.
• The warning system is available to save guard the various operations and components [7].

6 Milling Machine
Milling is the process of machining using rotary cutters to remove material which not only rotates
but advances towards or away from a workpiece.

6.1 Types of Milling Machine

Types of Milling
Machine

Vertical &
Horizontal Knee Type Ram Type Bed Type Planer Type
Milling Machine

6.1.1 Knee Type Milling Machine

The milling machine which has a knee like projection at the middle is called Knee – type milling
machine. It is characterized with a vertical adjustable worktable resting on a saddle that is
supported by a knee [8].
6.1.2 Ram Type Milling Machine
A milling machine which has a ram on the top of the column is called ram type milling machine.
Generally, ram is used in vertical milling machine [8].
6.1.3 Bed Type Milling Machine
It consists of sliding table which is mounted directly onto the massive bed of the machine and
cannot be raised or moved transversely, table movement is longitudinal only [8].
6.1.4 Planer Type Milling Machine
A planer is a type of metal working machine tool that uses linear relative motion between the
workpiece and cutting tool to cut the work piece. A planar is similar to a shaper accommodating
large moving workpieces whereas in a shaper; the cutting tool moves [8].
6.1.5 Horizontal Milling Machine
The Milling Machine in which the spindle axis is horizontal to the table is called horizontal Milling
Machine [8].

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6.1.6 Vertical Milling Machine
The Milling Machine in which the spindle axis is perpendicular to the table is called vertical
Milling Machine [8].

7 Parts of Vertical Milling Machine:

7.1 Base
It is situated where all parts of milling are sitting. It also carries the entire machine parts load so it
should have high compressive strength [9].
7.2 Over Arm
It is situated over the column on horizontal milling machine [9].
7.3 Knee
It is first moving part of milling machine. It is mounted on the column and move along slide ways
situated over the column. It moves in z – axis. It is driven manually or automatically [9].
7.4 Table
Table is situated over the knee. It is the part of machine which holds the workpiece while
machining. It has T slots cut over it. The work piece is clamped over it using clamping bolts.
• It provides vertical motion by moving the knee up and down
• It provides horizontal motion by feed screw
• It provides horizontal (transverse) motion by moving the saddle [9].

7.5 Vertical Head

It is upper section of vertical milling machine. It consists of spindle, driving motor and other
controlling mechanism [9].
7.6 Spindle
It is the main part of the machine which holds tool at right place in vertical milling machine. It is
moving part which is in rotary motion [9].
7.7 Ram
Ram is worked as overhanging arm in vertical milling machine. One end of the arm is attached to
the column and other end to the milling head [9].

8 Milling Operations
The different milling operations are as follows

Face Milling
This operation makes flat surface at the face of workpiece [10].
Side Milling
It is machining operation which produces flat vertical surface at the side of workpiece. This can
be done using side milling cutter [10].

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8.1 Plain Milling
It is a process of milling flat surfaces keeping the axis of the cutter parallel to the surface being
milled [10].

8.2 Straddle Milling

It is a process in which two side milling cutter is used to machined two opposite side of a workpiece
simultaneously [10].

8.3 Angular Milling

It is a process of milling flat surfaces which are neither parallel nor perpendicular to the axis of
the milling cutter. It is also called angular milling [10].
Gang Milling
It is the machining process in which two or more milling cutters are used together to perform
different milling operation simultaneously [10].

8.4 Form Milling

It is the process of machining special outline composed of curves, straight lines or entirely of
curves at a single cut [10].
Profile Milling
This milling operation is used to cut outer periphery of the workpiece [10].

8.5 End Milling

It is the process of producing flat surfaces which may be horizontal, vertical and at any angle taking
worktable as a reference [10].

8.6 Gear Milling

It is the milling process which is used to cut gears on the workpiece [10].

8.7 Helical Milling

This milling operation is done to produce objects having helical design such as helical gears and
twisted drills, drilling fine holes, etc [10].

8.8 Cam Milling

It is a machining process which is used to make cams. The cams are used to open and close of
the valves in the internal combustion engines [10].

8.9 Thread Milling

It is the process of milling used to cut threads on the cylindrical workpiece [10].

9 Advantages of Milling Machine

• An important advantage of vertical milling machine is the retractable quill, which moves
in and away from the cutting tool without need for cracking the worktable up and down.

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 • The material removal rate is faster in milling machine as the cutter has got multiple cutting
edges and rotate at high speed.
• This increases productivity, milling efficiency, and reducing the operator fatigue.
• It has ability to easily make angle cuts.
• Moreover, vertical milling machine has much simpler design than those of other milling
machines [11].

10 Disadvantages of Milling Machine

• The Cost of the milling machine is high.
• Its production cost is very high than drilling and shaper [11].

11 Advantages of CNC Milling Machine

• Machining is accurate
• Time taken to perform a job is very less
• Safe to operate
• Number of operators required to operate a machine are reduced
• No possibility of human error
• Reliable
• Even very complex designs can also be made
• Low maintenance required
• They are versatile
• Uniformity in designs
• They could run for all 24 hours a day [11].

12 Disadvantages of CNC Milling Machine

• They are costly
• Trained operator is required to operate the machine
• In case of breakdown a highly skilled professional is required to solve the problem [11].

13 BEST METHOD FOR MILLING

• In climb milling, the cutting tool is fed with the direction of rotation. Climb milling is always the
preferred method wherever the machine tool, fixture and workpiece will be allowed.
• In peripheral climb milling, the chip thickness will be decreased from the start of cut and it is zero
at the end of the cutting [12].

14 PRODUCT CHOSEN AND ITS MATERIAL

• We have selected the “connected rod” of the piston for the bike HONDA SFX model
2010.
• Aluminum can be used for manufacturing of connecting rod due to its light weight
preferred over steel and titanium materials and also has high shocking absorbing capacity.
• Aluminum alloys like aluminum 6061, aluminum 7075 can also be used instead of steel.
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 • Aluminum 6061-T6 is used for making the connecting rods in this CEP.

14.1 BASIC PROPERTIES

6061 has a density of 2.70 g/cm³ (0.0975 lb/in³).

14.1.1 Chemical Composition

The alloy composition of 6061 is:

• Silicon minimum 0.4%, maximum 0.8% by weight

• Iron no minimum, maximum 0.7%
• Copper minimum 0.15%, maximum 0.40%
• Manganese no minimum, maximum 0.15%
• Magnesium minimum 0.8%, maximum 1.2%
• Chromium minimum 0.04%, maximum 0.35%
• Zinc no minimum, maximum 0.25%
• Titanium no minimum, maximum 0.15%
• Other elements no more than 0.05% each, 0.15% total
• Remainder Aluminium

14.2 6061-T6
T6 temper 6061 has an ultimate tensile strength of at least 42,000 psi (290 MPa) and yield
strength of at least 35,000 psi (241 MPa). In thicknesses of 0.250 inch (6.35 mm) or less, it has
elongation of 8% or more; in thicker sections, it has elongation of 10%. [13].

14.3 MATERIAL FOR MANUFACTURING DESIRED PART

Figure 4 Material for manufacturing

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15 Surface finishing on Conventional Milling Machine

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16 2D VIEWS OF DESIRED PRODUCT
The 2D front and side views of desired product are below:

16.1 FRONT VIEW

Figure 5 Front view

16.2 SIDE VIEW

Figure 6 Side View

17 3D MODEL OF DESIRED PRODUCT

Figure 7 3D Model

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18 Programming codes used in CNC milling
O0001
N05 G91G21G80G40G49
N10 G00X170Y17.5M03
N15 M98P0012L20
O0011
N0001 G91G01X0Y10Z-1S960F60
N0002 G02X10Y-10R10F60
N0003 G02X-10Y-10R10F60
N0004 G02-10Y10R10F60
N0005 G02X10Y10F60R10
N0006 M99

N20 G00X0Y-10M05M09Z20
N25 G01G91X-102.5Y0
N30 M98P0013L20
O0012
N0001 G91G01X0Y7Z-1M03M08S1000F60
N0002 G02X7Y-7R7
N0003 G02X-7Y-7R7
N0004 G02X-7Y7R7
N0005 G02X7Y7R7
N0006 M99

N35G00X0Y-7M05M09Z20
N40 G90G21G80G40G49
N45 G00G54X0Y12S2500M03
N50 G43Z1H01M08
N55 G02X12Y12R12Z-12F50
N60 G02G91X11Y7R12Z-12F50
N65 G02X2Y-2Z-12R2F60
N70 G01X80Y0Z-12F60
N75 G03X2Y2Z-12R2F60
N80 G02X7Y3Z-12R8.5F60
N85 G02X9Y-9Z-12R8.5F70
N90 G02X-9Y-9Z-12R8.5F70
N95 G02X-7Y3Z-12R8.5F80
N100 G03X-2Y2Z-12R2F75
N105 G01X80Y0Z-12F85
N110 G03X-2Y-2Z-12R2F90

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N115 G03X2Y-2Z-12R2F90
N120 G02X-11Y-7Z-12R12F95
N125 G02X-12Y12Z-12R12F95
N130 G91G28Z00M09M05
N135 G28X0Y0
N140 G90G21G80G40G49
N150 G00G54X28Y2S3000M03
N155 G43Z1H01M08
N160 G01G91X80Y0Z-4F80
N165 G02X2Y-2R2Z-4F80
N170 G01X0Y-1Z-4F80
N175 G02X-2Y-2R2Z-4F85
N180 G01X-80Y0Z-4F85
N185 G02X-1Y1Z-4R1F90
N190 G01X0Y3Z-4F90
N195 G02X1Y1Z-4R1F90
N200 G91G28Z0M05M09
N205 G28X0Y0
N210 M30 [14].

19 Comparison
Conventional Machine CNC Machine
40 minutes were taken to make this part. The part was made within 20 minutes
including its program.
The dimensions of the machined part were not The dimensions of the part obtained were
so accurate as there was a difference of 0.2 mm exact as given.
regarding total length.
The surface finish was rough. The surface finish was smooth.

Big end bore outer diameter is 31.5 mm. Big hole outer diameter is 31.1 mm

Big end bore inner diameter is 25.4 mm. Big hole bore diameter is 25.5 mm

Small end bore outer diameter is 19 mm. Small end bore outer diameter is 19 mm.

Small end bore diameter is 13.3 mm Small end bore diameter is 13.4 mm

Length of whole workpiece is 106.1 mm. The length of whole workpiece is 106.2 mm

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20 Completion of product on milling machine

21 Completion of product on CNC milling machine

22 Results
The results obtained from CNC milling machine are more accurate than conventional milling
machine. So, after this assigned project, we prefer to use CNC milling machine for professional
working due to high accuracy for mass production.

23 Conclusion
After this experiment, it is concluded that the dimensions of the connecting rod obtained on CNC
are more precise and accurate. The part made out of CNC has a better surface finish than
conventional milling. Also, the time taken by the milling machine was too much while the CNC
made the part within minutes. So, in short, the CNC machine is better than the milling with the
advantage of accuracy and time management.

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