STUDY OF CNC MACHINES EXPT. NO: 1 DATE AIM: To study the basic components and details of CNC machine.

BASIC COMPONENTS: An operational CNC machine consist of i) Program of instruction ii) Machine control unit iii) Machine tool. PROGRAM OF INSTRUCTION: It is the detailed step by step instruction which tell the machine tool what to do. The program can input to the system either by manual data input or by a punched t ape. MACHINE CONTROL UNIT: It is also called as the controller unit. It is considered as the brain of the machine. It reads the part program and controls the machine tool operation. It consists of two units. (1) Data processing unit (2) Control loop unit. CONTROL LOOP UNIT: The control loop unit receives the data from data processing unit and converts it into control signals. The data usually provides the control information such as the new required position of each axis, its direction of motion and velocity and auxiliary control signals to relays. MACHINE TOOL: The machine which performs the machining operation is called machine tool. The machine tool consists of workable and spindle as well as the motor. It also includes the cutting tool work fixture and other auxiliary equipment needed in the operation. RESULT: Thus the basic components of CNC machine have been studied :

PART PROGRAMMING FUNDAMENTALS EXPT. NO: 2 DATE AIM: To know about part programming fundamentals for CNC turning. 1. CO-ORDINATE SYSTEM FOR A CNC LATHE: Machining of the work piece by an NC programming requires a coordinate system to be applied to the machine tool. As all machine tool have more than one slide, it is important that each slide is identified individually. There are three planes in which movements can take place: (1.) Longitudinal (2.) Transverse (3.) Vertical. Each plane is assigned a letter and is referred t o an axis (i.e.) (1.) Axis-x (2.) Axis-y (3.) Axis-z The three axis are identified by the upper case x, y and z and the direction of movement along each axis specified as either (+) or (-). The three axes are always at right angles and parallel to work holding surface. The zaxis is at right angles to both x and y axis. 2. MACHINE ZERO POINT: The manufacturers of the machine specify machine zero point. This is zero point for the co-ordinate system and reference point in the machine on turning the lathe. The machine zero point is generally at the center of the spindle nose face. The main spindle axis represents the z-axis, and the face determines x-axis. 3. WORK PIECE ZERO POINT: The point determines the work piece co-ordinate system in relation to the machine zero point. The work piece zero point is chosen by the programmer and :

the input to the system. 4. NC PROGRAM BUILT UP: In an NC program, the machining system operations for producing a part on the machine tool are laid down in a form that the control system can understand. A program is composed of several block s. A block is a collection of NC works. An NC word is collection of address, letter and sequence of number. BASIC COMPONENTS: An operational CNC machine consists of (i) Program of instruction (ii) Machine control unit (iii) Machine tool. PROGRAM OF INSTRUCTION: It is the detailed step by step instruction which tell the machine tool what to do. The program can input to the system either by manual data input or by a punched t ape. MACHINE CONTROL UNIT: It is also called as the controller unit. It is considered as the brain of the machine. It reads the part program and controls the machine tool operation. It consists of two units. (1) Data processing unit (2) Control loop unit. CONTROL LOOP UNIT: The control loop unit receives the data from data processing unit and converts it into control signals. The data usually provides the control information such as the new required position of each axis, its direction of motion and velocity and auxiliary control signals to relays. MACHINE TOOL: The machine which performs the machining operation is called machine tool. The machine tool consists of workable and spindle as well as the motor. It also includes the cutting tool work fixture and other auxiliary equipment needed in the operation. CNC Systems:

Point-to-point control is the positioning of the tool from one y point to

another within a coordinate system. Most often used for positioning to a point where a manual machining operation such as drilling or boring would occur.

Straight-cut control has the ability move a tool, while engaged, y straight in all axes of the machine and has the ability to do angles of 45 degrees.

Contouring control systems generate a continuously controlled y tool path by interpolating intermediate points or coordinates. Interpolating means the ability to generate the points that make up a path.

Cutting Data and Formulae: Here are some of the most common terms used for expressing cutting data:

Spindle speed - Spindle speed is the rotational speed of the spindle and tooling. This value is usually expressed in RPM. (Revolutions per Minute).

Feed rate value - The feed rate value is the numerical value at which a tool will traverse a work piece. It is usually expressed in either IPM (Inches per Minute) or IPR (Inches per Revolution).

Cutting speed - Cutting speed is the rotational speed of the cutting tool or work piece. It can be stated as either RPM or SFM. (Surface Fee Per Minute).

Depth of Cut - Depth of cut is the distance the tool tip is engaged into the wor piece. It is incorporated into the X, Y, and Z values in a CNC program. Separate from the program, it can be expressed in inches or mm

Tooling Requirements: Tooling requirements and selection are based on part restrictions and industry manufacturing practices. Most of these ideas are common sense thoughts. Good

CNC programmers and operators should be aware of them. Know the material to be machined and its characteristics. Use industry standard catalog tooling to cut costs.

Make use of technical services offered by tooling manufacturers. Quality of the fixture should be based on the number of pieces that will eventually be produced. Always use the right tool for the right machining operation. Keep spares or backups of tooling in the event resharpening is needed or tool breakage occurs.

Keep an assortment of tooling in case one type does not perform the job as desired. Use high speed steel tools on easily machined materials. Use carbide tools on difficult to cut materials. Use cobalt or oxide coated tools for exotic alloys.

Use inserts type tooling where possible t o cut costs. Consider using reamers, instead of boring bars, on lathe applications where chatter and chip control may be a problem

Be aware of the flexing that occurs with long length tools. Extra passes may be required to eliminate tapering and chattering. Unit Systems and Input Modes: Unit Systems are the units of measurement to be used for the CNC program. All machines understand both English and Metric standards. When programming in English units you are using inches. And in metric its the millimeter (mm.). The CNC machine needs to be told which units are being used. Some machines are automatically set-up at the factory for inches specify inches or G71 to specify mm.. Input modes refer to the type of coordinate information that is input into the or mm. Normally at the beginning of a CNC program you will see either; G70 to

program for the CNC machine. There are two types. Absolute input , designated by the G90 c ode, specifies distances from the origin or program zero point. Absolute is the most common mode. Incremental input , designated by the G91 code, specifies distances and directions based on the previous point as an origin. Incremental input is sometime called point-to-point. All CNC systems can be switched from absolute to incremental mode and back unlimited times within a program. Other input modes such as Helical also exist

PREPARATORY FUNCTIONS (G codes)

The G-codes are the codes that position the tool and do the actual work, as opposed to M-codes, that manages the machine; T for tool-related codes. S and F are tool-Speed and tool-Feed, and finally D-codes for tool compensation. The programming language of Numerical Control (NC) is sometimes informally called G-code. But in actuality, G-codes are only a part of the NC-programming language that controls NC and CNC machine tools. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. G00 - Rapid move (not cutting) G01 - Linear move G02 - Clockwise circular motion G03 - Counterclockwise circular motion G04 - Dwell G05 - Pause (for operator intervention) G08 - Acceleration G09 - Deceleration G17 - x-y plane for circular interpolation G18 - z-x plane for circular interpolation G19 - y-z plane for circular interpolation G20 - turning cycle or inch data specification G21 - thread cutting cycle or metric data specification G24 - face turning cycle G25 - wait for input #1 to go low (Prolight Mill) G26 - wait for input #1 to go high (Prolight Mill) G28 - return to reference point G29 - return from reference point G31 - Stop on input (INROB1 is high) (Prolight Mill) G33-35 - thread cutting functions (Emco Lathe) G35 - wait for input #2 to go low (Prolight Mill) G36 - wait for input #2 to go high (Prolight Mill) G40 - cutter compensation cancel G41 - cutter compensation to the left

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53.

G42 - cutter compensation to the right G43 - tool length compensation, positive G44 - tool length compensation, negative G50 - Preset position G70 - set inch based units or finishing cycle G71 - set metric units or stock removal G72 - indicate finishing cycle (EMCO Lathe) G72 - 3D circular interpolation clockwise (Prolight Mill) G73 - turning cycle contour (EMCO Lathe) G73 - 3D circular interpolation counter clockwise (Prolight Mill) G74 - facing cycle contour (Emco Lathe) G74.1 - disable 360 deg arcs (Prolight Mill) G75 - pattern repeating (Emco Lathe) G75.1 - enable 360 degree arcs (Prolight Mill) G76 - deep hole drilling, cut cycle in z-axis G77 - cut-in cycle in x-axis G78 - multiple threading cycle G80 - fixed cycle cancel G81-89 - fixed cycles specified by machine tool manufacturers G81 - drilling cycle (Prolight Mill) G82 - straight drilling cycle with dwell (Prolight Mill) G83 - drilling cycle (EMCO Lathe) G83 - peck drilling cycle (Prolight Mill) G84 - taping cycle (EMCO Lathe) G85 - reaming cycle (EMCO Lathe) G85 - boring cycle (Prolight mill) G86 - boring with spindle off and dwell cycle (Prolight Mill) G89 - boring cycle with dwell (Prolight Mill) G90 - absolute dimension program

54. 55. 56. 57. 58. 59. 60. 61. 62. 63.

G91 - incremental dimensions G92 - Spindle speed limit G93 - Coordinate system setting G94 - Feed rate in ipm (EMCO Lathe) G95 - Feed rate in ipr (EMCO Lathe) G96 - Surface cutting speed (EMCO Lathe) G97 - Rotational speed rpm (EMCO Lathe) G98 - withdraw the tool to the starting point or feed per minute G99 - withdraw the tool to a safe plane or feed per revolution G101 - Spline interpolation (Prolight Mill)

MISCELLANIOUS FUNCTION (M CODES): M codes are instructions describing miscellaneous functions like calling the tool, spindle rotation, coolant supply etc. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. M00 - program stop M01 - optional stop using stop button M02 - end of program M03 - spindle on CW M04 - spindle on CCW M05 - spindle off M06 - tool change M07 - flood with coolant M08 - mist with coolant M08 - turn on accessory #1 (120VAC outlet) (Prolight Mill) M09 - coolant off M09 - turn off accessory #1 (120VAC outlet) (Prolight Mill) M10 - turn on accessory #2 (120VAC outlet) (Prolight Mill) M11 - turn off accessory #2 (120VAC outlet) (Prolight Mill) or tool change M17 - subroutine end

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

M20 - tailstock back (EMCO Lathe) M20 - Chain to next program (Prolight Mill) M21 - tailstock forward (EMCO Lathe) M22 - Write current position to data file (Prolight Mill) M25 - open chuck (EMCO Lathe) M25 - set output #1 off (Prolight Mill) M26 - close chuck (EMCO Lathe) M26 - set output #1 on (Prolight Mill) M30 - end of tape (rewind) M35 - set output #2 off (Prolight Mill) M36 - set output #2 on (Prolight Mill) M38 - put stepper motors on low power standby (Prolight Mill) M47 - restart a program continuously, or a fixed number of times (Prolight Mill) M71 - puff blowing on (EMCO Lathe) M72 - puff blowing off (EMCO Lathe) M96 - compensate for rounded external curves M97 - compensate for sharp external curves M98 - subprogram call M99 - return from subprogram, jump instruction M101 - move x-axis home (Prolight Mill) M102 - move y-axis home (Prolight Mill) M103 - move z-axis home (Prolight Mill)

SPECIAL CYCLES Special Cycles or Canned Cycles are a preprogrammed sequences of repetitive tool motion that are built into the control system f or common operations such as drilling, tapping, boring, and pocketing. Its purpose is to reduce the

amount of program code that would normally have to be written. Canned cycles are G codes that are options purchased with a CNC, but some are standard equipment depending on the manufacturer.

Drilling cycle

(G81, G82 or G83) are used to drill multiple holes

without programming each move separately. Using this cycle reduces the amount of code that would normally have to be written.

Facing cycle (G77) is used to clean up rough stock material (normally on top of the part) which can be located within a rectangular area. Using this cycle reduces the amount of code that would normally have to be written.

Rectangular pocket cycle (G78) is used to clear out material which is located within a rectangular area. Using this cycle reduces the amount of code that would normally have to be written.

Circular pocket cycle (G79) is used to clear out material which is located within a circular area. Using this cycle reduces the amount of code that would normally have to be written.

RESULT: Thus the part programming fundamentals of CNC Machining is studied

PLAIN FACING AND TURNING EXPT. NO: 3 DATE :

AIM: To simulate the cnc program for given work piece according to the dimensions. PROGRAM: N10 G21 G98 N20 G28 U0 W0 N30 M06 T01 N40 M03 S1200 N50 G00 Z2 N60 G00 X28 N70 G94 X-0.5 Z-0.5 Z-1 Z-1.5 Z-2 N80 G71 U.5 R1 N90 G71 P100 Q130 U.1 W.1 F80 N100 G01 X22 Z0 N110 G01 X22 Z-50 N120 G01 X28 Z-50 N130 G01 X28 Z2 N140 G28 U0 W0 N150 M05 N160 M30

RESULT: Thus, the plain facing and turning operations were simulated on the given work piece according to the dimensions.

All dimensions are in mm

STEP TURNING AND FACING

EXPT. NO: 3 DATE :