Week 14
Wildcard Week
During Wildcard Week, I worked on a three-axis CNC milling machine as part of the multi-axis machining module. The objective was to design and manufacture a nameplate featuring my name, Shantanu Kadam.
To accomplish this, I learned the fundamentals of CNC programming using FANUC G-code and M-code standards, which are widely used in industrial CNC machines. I developed a machining program manually using FANUC-compatible code, defining the toolpaths, spindle operations, feed rates, and cutting cycles required for the operation.
After writing and verifying the program, I executed it on the CNC milling machine. The machine precisely milled the nameplate as per the given instructions, demonstrating the practical application of FANUC-based programming.
This hands-on experience significantly enhanced my understanding of CNC machining, FANUC programming language, and the overall workflow of a three-axis milling process.
For this activity, I used an acrylic plate of dimensions 300 mm × 150 mm × 15 mm as the workpiece material. I manually wrote the CNC program using FANUC G-code and M-code standards, which are commonly used in industry for CNC operations. The program defined the required toolpaths, spindle speed, feed rates, and machining cycles.
To begin the process, I first selected Notepad as the text editor for writing the CNC program. Using G-code and M-code based on FANUC standards, I manually wrote the program required for machining. The program was written as follows:
Programe for Name Plate
#BILLET X300 Y150
M03 S3000
N05 G00 X0 Y0 Z0
N10 G01 Z-5
N15 G01 X17 Y0 F50
N20 G03 X17 Y20 R10 F30
N25 G01 X10 Y20 F50
N30 G02 X10 Y40 R10 F30
N35 G01 X27 Y40 F50
N40 G01 Z2
N45 G01 X37 Y0 F100
N50 G01 Z-5
N55 G01 X37 Y0 F100
N60 G01 Y40 F50
N65 G01 Y20 F50
N70 G01 X61 F50
N71 G01 Y40 F50
N72 G01 Y0 F50
N73 G01 Z2
N74 G01 X71 Y0 F50
N75 G01 Z-5
N76 G01 X83 Y40 F50
N77 G01 X95 Y0 F50
N78 G01 Z2
N79 G01 X90.5 Y15 F50
N80 G01 Z-5
N81 G01 X75.5 Y15 F50
N82 G01 Z2
N83 G01 X105 Y0 F100
N83 G01 X105 Y0 F100
N84 G01 Z-5
N85 G01 X105 Y40 F50
N86 G01 X129 Y0 F50
N87 G01 X129 Y40 F50
N88 G01 Z2
N89 G01 X139 Y40 F50
N90 G01 Z-5
N91 G01 X163 Y40 F50
N92 G01 X151 Y40 F50
N93 G01 X151 Y0 F50
N94 G01 Z2
N95 G01 X173 Y0 F50
N96 G01 Z-5
N97 G01 X185 Y40 F50
N98 G01 X197 Y0 F50
N99 G01 Z2
N100 G01 X192.5 Y15 F50
G01 Z-5
N101 G01 X177.5 Y15 F50
N102 G01 Z2
N103 G01 X207 Y0 F50
N104 G01 Z-5
N105 G01 X207 Y40 F50
N106 G01 X231 Y0 F50
N107 G01 X231 Y40 F50
N107 G01 Z2
N108 G01 X241 Y40 F50
N109 G01 Z-5
N110 G01 X241 Y12 F50
N111 G03 X265 Y12 R12 F30
N112 G01 X265 Y40 F50
N113 G01 Z2
N114 G01 X55 Y-20
N115 G01 Z-5
N116 G01 X55 Y-60 F50
N117 G01 X55 Y-40 F50
N118 G01 X79 Y-20 F50
N119 G01 X55 Y-40 F50
N119 G01 X79 Y-60 F50
N120 G01 Z2
N121 G01 X89 Y-60 F100
N122 G01 Z-5
N123 G01 X101 Y-20 F50
N124 G01 X113 Y-60 F50
N125 G01 X108.5 Y-45 F50
N125 G01 X93.5 Y-45 F50
N127 G01 Z2
N128 G01 X123 Y-60 F100
G01 Z-5
N129 G01 X127 Y-60 F50
N130 G03 X127 Y-20 R20 F30
N131 G01 X123 Y-20 F30
N132 G01 X123 Y-60 F50
N133 G01 Z2
N134 G01 X157 Y-60 F100
N135 G01 Z-5
N136 G01 X169 Y-20 F50
N137 G01 X181 Y-60 F50
N137 G01 X181 Y-60 F50
N138 G01 X176.5 Y-45 F50
N139 G01 X161.5 Y-45 F50
N140 G01 Z2
N141 G01 X191 Y-60 F100
G01 Z-5
N142 G01 X191 Y-20 F50
N143 G01 X203 Y-40 F50
N144 G01 X215 Y-20 F50
N145 G01 X215 Y-60 F50
N146 Z50
M05 M30
Once the program was completed, the next step was to proceed to the CNC milling machine for the execution of the program.
In the next step, I powered on the CNC milling machine and the desktop control system used to operate and monitor the machine.
I then opened the CNC milling software and navigated to the File menu. From there, I selected the Milling Program option. Within the list, I located and selected the program I had previously saved under the name Shantanu. After selecting the desired file, I clicked on Open to load the program into the CNC milling software.
The program was then successfully loaded into the milling software and was ready for execution on the CNC machine.
I then navigated to the Settings menu, followed by the Jog menu, to configure and position the milling machine for further operation.
With the Jog menu opened on the monitor, I used it to manually position and prepare the machine for the upcoming machining operations.
Next, I proceeded to the machine bed to mount the workpiece. I carefully positioned the plate on the bed and secured it firmly using clamps and a spanner to ensure it remained stable during the machining process.
I then returned to the Jog menu to set the origin point (work zero) for the machining process, ensuring accurate alignment of the tool with the workpiece.
By adjusting the X, Y, and Z coordinates in the Jog menu, I accurately set the origin point for the cutting operation, ensuring proper alignment for the next machining step.
I then navigated to the Jog menu and set the X, Y, and Z coordinates to 0, 0, 0, establishing the machine's origin. After confirming the settings, I closed the Jog menu to proceed with the operation.
After setting the origin, I navigated to the Program menu, selected Program Mode, and initiated the Execution command. Once execution was activated, the CNC milling machine began operating according to the loaded program.
As the machine started, the spindle began rotating at 3000 RPM. The tool then moved to the set position and initiated the cutting operation as per the programmed toolpath.
As the machine advanced, the program executed sequentially, guiding the tool through the defined path to complete the machining process.
Once the program was completed, the machining process finished successfully and my nameplate was ready. I carefully removed the finished workpiece from the machine bed and cleaned it using a wire brush to remove any burrs or debris.
As the nameplate was ready, I designed a stand to hold it at a 45-degree angle for an improved visual presentation. The design was then cut using a laser cutting machine on MDF material.
Once the stand was ready, I mounted the nameplate onto it.
