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Create an NC program, to simulate the machining of the desk tray shown in
Fig. 1.1 Programming takes place through the MTS TOPCAM V7.4 Simulator.
Prepare the setup sheet using the following information.
Given:

Material: Aluminum (Almg1).

Blank dimensions: 100 x 50 x 15 mm.

Cutting tools to be selected from Table 1.1.

Max. Spindle rotational speed limit: 3000 RPM.

The finished work part should look like the part shown in Fig.1.2.

Surface cutting speed m/min for Aluminum to be selected from Table 1.2.

Cutting speeds rpm and feeds mm/min limits for different milling operations
when machining Aluminum to be selected from Table 1.3
Required Output:

Create an NC program to simulate the machining of the desk tray shown in
Fig. 1.1 using the MTS TOPCAM V7.4 Simulator.

Calculate the points of intersection on profiles if not shown on the drawings.

Select the appropriate tools required to create the program from Table 1.1.

Set the machining conditions (feed, speed, depth of cut …) required for proper
machining.

0.5 mm facing is required on the top side of the work part.
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Technical drawing.
Section A-A
Note: All dimensions are in mm.
Fig 1.1: Detailed technical drawing of the finished part.
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List of Tools
1. Shell End Mill
WSF 40x32x16 R_AFD-30 32x37(17)"
WSF 50x36x22 R_AFD-30 40x37(19)"
2. Angular Cutter Tp B
WF-B45 14x4(60) R_SZF-30 ER16x41"
WF-B45 12x3(55) R_SZF-30 ER16x41"
WF-B45 20x5(63) R_SZF-30 ER25x41"
4.Slot Drill
BNF-B 8x11(61) R_SZF-30 ER16x41"
BNF-B 10x13(63) R_SZF-30 ER16x41"
BNF-B 12x16(73) R_SZF-30 ER25x41"
BNF-B 6x8(52) R_SZF-30 ER16x41"
Table 1.1: List of cutting tools
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Machining Steps:
1. Facing
2. Boring
3. Rectangular pocket cutting
4. Circular pocket cutting
5. Bore finishing
6. Chamfering
It is up to the programmer to choose the suitable setup parameters according to the
material and the dimensions of the finished work part. Table 1.3 shows the cutting
speeds and feeds limits for different milling operations when machining Aluminum.
Fig 1.2 (a)
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Fig 1.2 (b)
Fig 2.2: (a) Finished part 3D view1. (b) Finished part 3D view2.
Cutting speeds limits for different metals.
Metal Type
Cutting speed in meters/min
Cast Iron
20-28
Mild Steel
18-25
High Speed Steel
12-18
Brass
45-90
Bronze
15-21
Aluminum
Up to 300
Table 1.2: Cutting speed limits for different metals
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Aluminum cutting speeds and feeds limits for different milling operations.
Operation
Speed
Feed
500 rpm
200 mm/min
Drilling or boring small holes 1-7 mm diameter
1500 rpm
100 mm/min
> 7 mm diameter
1000 rpm
100 mm/min
1000 rpm
150 mm/min
Facing
Drilling or boring large holes
Pockets cutting
Table 1.3: Aluminum cutting speeds and feeds limits for different milling operations.
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