The document describes a project at Yanbu Industrial College to improve operations on an EMCO Mill 155 CNC machine. The objectives were to fully operate the machine and add capabilities to solve problems with zero point setting, tool offsets, and job clamping. A new vice was designed to increase the size of parts that could be clamped. The zero point and tool length measurement process was also improved to reduce setup time and enhance machining operations. An example program is provided to machine a coupling using the new vice and settings.

1. Yanbu Industrial College
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2. 2

3. 1- Project objectives.
2- Introduction.
3- Mission of the project.
4-The work done.
a- Job clamping.
b- Zero point setting.
c- Tool length measurement.
5-T he example.
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4. THEOBJECTIVE
To operate EMCO Mill 155 machine
fully and to add more facilities to it
to enhance and maximize it’s
operations.
Also, to solve some problems which
affect the machine setting time.
These problems can be summarized
in:
• Zero setting position.
•Tools offset.
• Job clamping
Operate fully
Adding facilities
Solve some problems
Example
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5. Themetalcuttingoperations
(machining)isoneofthemost
importantmanufacturingprocessesin
industry.
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INTRODUCTION

6. 6
Numerical Control (NC) : means
control by numbers.
Computer Numerical Control
(CNC) is any computer-controlled
device that can be programmed to
perform a task (machining
operations).

7. ElementsToACNCProjectbyusingWinCAMprogram
7
Machining
3D-simulation
CAM
CAD
NC program

8. Concept EMCOMill155Specification…
 Travel (X/Y/Z) : 300/200/300 mm
 Milling table (L *W) : 520 * 180 mm
 Spindle speed range : 150-5000 or
1000 R/min
 Machine weight : 700 kg
 Power supply :400 v , 50/60 Hz
 Machine dimensions (L*D*H) :
1502*1284*1925 mm
 3 axis CNC machining center.
 Integrated PC and 12" flat display.
 Hardened guide ways.
 Central lubrication.
 Machine lamp.
 Fully enclosed inclusive chip tray.
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9. TheMission
To study the EMCO mill 155
machine clamping process
improvement; to increase the
capability of job clamping.
Also to reduce setting time
and enhance machining
operations.
1-Job Clamping
3-Tool length measurement
2-Zero setting point
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10. 10

11. JobClamping
The machine pneumatic vice
can carry only rectangular jobs
of exact dimensions of 140
mm X 100 mm and round jobs
of only 30 mm & 40 mm.
Hence one of the objectives is
to increase the machine
capacity to carry different job
sizes by designing a new vice.
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12. 12
Job
Clamping
Brain
Storming
Design
Drawing
Machining

13. 13
design drawing

14. 14

15. 15
New mechanical device The original device

16. 16

17. ZeroPointsetting
The job zero point is set at the
pneumatic vice left back carrier. If
any different job setting is used,
then the machine will lose the X and
Y position. So in the new vice a new
setting is needed. (The zero point
must be kept because the system
needs it for FMS work)
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This position is for new vice
• For X and Y position
• Transfer X to (+19.9 mm)
• Transfer Y to (+ 3.2 mm + 100 mm)

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For Z axis
• Z (varies) = (standard number 184.540 mm ) – (vice
material thickness + height of the work piece)
• Vice material thickness (9.6 mm)
height of the
work piece
vice material
thickness

20. 20

21. ToollengthMeasuring(tool-offset)
Tools used to be set by try
and error. A system is
designed to measure the
exact tool length.Then
the tool length is register
on the machine tools
offset.
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22. Measuringdevice
22
L

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To set Z axis:
1- Measure tool length and register it in the machine control.
2-Touch on the vice face (base 184.54 mm) and recording the
number.
3- Subtract 9.6 mm (vice material thickness) from the
recorded number.
(If the job height is 50mm thenThe final value for X is 124.818
mm.)
Tool length measuring procedure

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offset of Z = touch over the vice (constant =184.54
mm ) – touch over the job
offset of Z = 184.54 – 124.818 = 59.72 mm
Then register the offset on the commandTRANS
(eg. TRANSE Z59.72 ).
Example:

25. Example
"Old ham's Coupling" is machined
by using the mentioned settings:
The coupling consists of three pieces
with a diameter of 70 mm and
height of 40 mm and to be made
from polystyrene(Teflon) material.
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N0005 G54
TRANS X19.9 Y3.2 Z49.6
N0020 F100
N0025 S1000
N0030 T7 D1 M6
N0045 G0 X17.525 Y40. M3
N0050 G1 Z0.
N0055 G1 X17.525 Y62.475
N0060 G1 Z-10. F100
N0065 X17.525 Y17.525 F100
N0070 G1 X23.788 Y17.525
N0075 X23.787 Y68.737
N0080 X11.262 Y68.737
N0085 X11.263 Y11.262
N0090 X23.788 Y11.262
N0095 G1 X30.05 Y11.262
N0100 X30.05 Y75.
N0105 X5. Y75.
N0110 X5. Y5.
N0115 X30.05 Y5.
N0120 G1 X30.05 Y40.
N0125 G3 X17.525 Y40. I-6.263 J0.
N0130 G0 X17.525 Y40. Z20.
N0135 G94 F100 G97 S1000
N0140 G0 X62.475 Y40. M3
N0145 G1 Z0.
N0150 G1 X62.475 Y17.525
N0155 G1 Z-10. F100
N0160 X62.475 Y62.475 F100
N0165 G1 X56.213 Y62.475
N0170 X56.212 Y11.262
N0175 X68.737 Y11.262
N0180 X68.738 Y68.738
N0185 X56.213 Y68.738
N0190 G1 X49.95 Y68.738
N0195 X49.95 Y5.
N0230 M30
TheJobExample

27. Thank you
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