Manufacturing Process

CNC TECHNOLOGY

Manufacturing System Laboratory

Dept of Industrial Engineering - ITS
Jurusan Teknik Industri FTI - ITS

Transferred skill Results

muscle power engine driven machine First industrial

tools revolution
manipulating skill mechanization hard automation
vision skill use of position increase of accuracy,
transducers, cameras part recognition
brain power cnc machines, industrial second industrial
robots, soft automation,
revolution
computer control of
manufacturing systems

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Utilization of computers in manufacturing applications

has proved to be one of the most significant
developments over the last couple of decades in helping
to improve the productivity and efficiency of
manufacturing systems.

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The metal cutting operations (also called machining) is one

of the most important manufacturing processes in
industry today (as it was yesterday).

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MACHINING IS THE REMOVAL OF

MATERIALS IN FORMS OF CHIPS FROM
THE WORKPIECE BY SHEARING WITH
A SHARP TOOL.

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The main function of a machine tool is to control the

workpiece-cutting tool positional relationship in such a
way as to achieve a desired geometric shape of the
workpiece with sufficient dimensional accuracy.

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Machine tool provides:

work holding
tool holding
relative motion between tool
and workpiece

primary motion
secondary motion
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Primary motion

Relative motion
Secondary motion
between tool and
workpiece

Cutting motion Feed motion

Cutting Feed rate

speed
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m a c h i n e c o n t r o l u n i t

p o s i t i o n t r a n s d u c e r s

w o r k h o l d i n g d e v i c e

t o o l h o l d i n g d e v i c e

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CLASSIFICATION OF THE CHIP REMOVING METHODS

ACCORDING TO THE RELATIVE MOTION

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CLASSIFICATION OF MACHINE TOOLS

THOSE USING THOSE USING THOSE USING

SINGLE MULTIPOINT ABRASIVE
POINT TOOLS TOOLS
TOOLS
lathes drilling m/c’s grinding m/c’s
shapers milling m/c’s honing m/c’s
planers broaching m/c’s etc.
boring m/c’s hobbing m/c’s
etc. etc.

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ISO MACHINE TOOL AXIS DEFINITION

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ISO MACHINE TOOL AXES DEFINITIONS
AXIS MACHINE TOOL WITH SPINDLE MACHINE TOOL WITH
NO SPINDLE

Z axis of spindle, perpendicular to work

(+Z) as tool goes away from the work piece holding surface, (+Z) as
tool goes away from the
workpiece

MACHINE MACHINE TOOL WITH

TOOL WITH ROTATING TOOL
ROTATING
WORKPIECE

HORIZONT VERTICAL
AL AXIS AXIS

X radial and horizontal horizontal parallel to and positive in

parallel to and parallel and parallel the principal direction of
cross slide, to work to the work cutting (primary motion)
(+X) when holding holding
tool goes away surface, surface,
from the axis (+X) to the (+X) to the
of spindle right when right when
viewed viewed
from from
spindle spindle
towards towards
work piece column

Y apply right hand rules 13

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RIGHT HAND RULE

Vertical Machine Horizontal Machine

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STANDARD LATHE
COORDINATE SYSTEM

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STANDARD MILLING MACHINE

COORDINATE SYSTEM

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NUMERICALLY CONTROLLED MACHINE

TOOLS:
An NC machine tool is functionally the same as a
conventional machine tool. The technological
capabilities NC machine tools in terms of
machining are no different from those of
conventional ones. The difference is in the way in
which the various machine functions and slide
movements are controlled.
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The functions and motions such as;

turning the spindle on and off

setting cutting speeds
setting feed rate
turning coolant on and off
moving tool with respect to workpiece

are performed by Machine Control Unit (MCU) in

NC machine tools.

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INTRODUCTION TO CNC

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HISTORY
 US Air Force commissioned MIT to develop the
first "numerically controlled" machine in 1949. It
was demonstrated in 1952.
 At 1970-1972 first Computer Numeric Control
machines were developed.
 Today, computer numerical control (CNC)
machines are found almost everywhere, from
small job shops in rural communities to
companies in large urban areas.

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DEFINITION
 In CNC (Computer Numerical Control), the
instructions are stored as a program in a micro-
computer attached to the machine. The
computer will also handle much of the control
logic of the machine, making it more adaptable
than earlier hard-wired controllers.

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CNC APPLICATIONS
 Machining
2.5D / 3D
Turning ~ Lathes, Turning Centre
Milling ~ Machining Centres
 Forming
2D
Plasma and Laser Cutting
Blanking, nibbling and punching
3D
Rapid Prototyping
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SAMPLE
CNC MACHINES

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CNC TURNING

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CNC MILLING

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CNC LASER CUTTING

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CNC PLASMA CUTTING

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CNC PRESS

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CNC RAPID PROTOTYPING

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INDUSTRIES MOST AFFECTED

by CNC
 Aerospace
 Machinery
 Electrical
 Fabrication
 Automotive
 Instrumentation
 Mold making

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SAMPLE PRODUCTS
OF
CNC MANUFACTURING

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AUTOMOTIVE INDUSTRY
Engine Block

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AUTOMOTIVE INDUSTRY(Cont’d)
Different Products

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AEROSPACE INDUSTRY -Aircraft Turbine Machined by

5-Axis CNC Milling Machine

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CNC MOLD MAKING

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ELECTRONIC INDUSTRY

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RAPID PROTOTYPING
PRODUCTS

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ADVANTAGES of CNC
 Productivity
Machine utilisation is increased because
more time is spent cutting and less time is
taken by positioning.
Reduced setup time increases utilisation
too.

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ADVANTAGES of CNC
 Quality
Parts are more accurate.
Parts are more repeatable.
Less waste due to scrap.

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ADVANTAGES of CNC

 Reduced inventory
Reduced setup time permits smaller
economic batch quantities.
Lower lead time allows lower stock levels.
Lower stock levels reduce interest charges
and working capital requirements.

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ADVANTAGES of CNC
 Machining Complex shapes
Slide movements under computer control.
Computer controller can calculate steps.
First NC machine built 1951 at MIT for
aircraft skin milling.

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ADVANTAGES of CNC
 Management Control
CNC leads to CAD
Process planning
Production planning

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DRAWBACKS of CNC
 High capital cost
Machine tools cost $30,000 - $1,500,000
 Retraining and recruitment of staff
 New support facilities
 High maintenance requirements
 Not cost-effective for low-level production on simple parts
 As geometric complexity or volume increases CNC becomes
more economical
 Maintenance personnel must have both mechanical and
electronics expertise

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CNC SYSTEM ELEMENTS

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CNC SYSTEM ELEMENTS

A typical CNC system consists of the

following six elements
 Part program
 Program input device
 Machine control unit
 Drive system
 Machine tool
 Feedback system

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NC SYSTEM ELEMENTS

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OPERATIONAL FEATURES of CNC

MACHINES

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PART PROGRAM
 A part program is a series of coded instructions required to
produce a part. It controls the movement of the machine
tool and the on/off control of auxiliary functions such as
spindle rotation and coolant. The coded instructions are
composed of letters, numbers and symbols and are
arranged in a format of functional blocks as in the following
example
N10 G01 X5.0 Y2.5 F15.0
| | | | |
| | | | Feed rate (15 in/min)
| | | Y-coordinate (2.5")
| | X-coordinate (5.0")
| Linear interpolation mode
Sequence number

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PROGRAM INPUT DEVICE

 The program input device is the mechanism for
part programs to be entered into the CNC
control. The most commonly used program input
devices are keyboards, punched tape reader,
diskette drivers, throgh RS 232 serial ports and
networks.

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MACHINE CONTROL UNIT

The machine control unit (MCU) is the heart of a CNC
system. It is used to perform the following functions:

 Read coded instructions

 Decode coded instructions
 Implement interpolations (linear, circular, and helical) to
generate axis motion commands
 Feed axis motion commands to the amplifier circuits for
driving the axis mechanisms
 Receive the feedback signals of position and speed for each
drive axis
 Implement auxiliary control functions such as coolant or
spindle on/off, and tool change

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TYPES of CNC CONTROL

SYSTEMS

 Open-loop control
 Closed-loop control

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OPEN-LOOP CONTROL SYSTEM

 In open-loop control system step motors are used
 Step motors are driven by electric pulses
 Every pulse rotates the motor spindle through a certain
amount
 By counting the pulses, the amount of motion can be
controlled
 No feedback signal for error correction
 Lower positioning accuracy

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CLOSED-LOOP CONTROL SYSTEMS

 In closed-loop control systems DC or AC motors
are used
 Position transducers are used to generate
position feedback signals for error correction
 Better accuracy can be achieved
 More expensive
 Suitable for large size machine tools

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DRIVE SYSTEM
 A drive system consists of amplifier circuits, stepping
motors or servomotors and ball lead-screws. The MCU
feeds control signals (position and speed) of each axis to
the amplifier circuits. The control signals are augmented to
actuate stepping motors which in turn rotate the ball lead-
screws to position the machine table.

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STEPPING MOTORS
 A stepping motor provides open-loop, digital control of the
position of a workpiece in a numerical control machine. The
drive unit receives a direction input (cw or ccw) and pulse
inputs. For each pulse it receives, the drive unit
manipulates the motor voltage and current, causing the
motor shaft to rotate bya fixed angle (one step). The lead
screw converts the rotary motion of the motor shaft into
linear motion of the workpiece .

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STEPPING MOTORS

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RECIRCULATING BALL SCREWS

Transform rotational motion of the motor into
translational motion of the nut attached to the machine
table.

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RECIRCULATING BALL SCREWS

 Accuracy of CNC
machines depends on
their rigid
construction, care in
manufacturing, and
the use of ball screws
to almost eliminate
slop in the screws
used to move portions
of the machine.
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POSITIONING
 The positioning resolution of a ball screw drive mechanism
is directly proportional to the smallest angle that the motor
can turn.
 The smallest angle is controlled by the motor step size.
 Microsteps can be used to decrease the motor step size.
 CNC machines typically have resolutions of 0.0025 mm or
better.

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MACHINE TOOL
 CNC controls are used to control various types of machine
tools. Regardless of which type of machine tool is
controlled, it always has a slide table and a spindle to
control of position and speed. The machine table is
controlled in the X and Y axes, while the spindle runs along
the Z axis.

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FEEDBACK SYSTEM
 The feedback system is also referred to as the measuring
system. It uses position and speed transducers to
continuously monitor the position at which the cutting tool
is located at any particular time. The MCU uses the
difference between reference signals and feedback signals
to generate the control signals for correcting position and
speed errors.

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CNC MACHINES FEEDBACK

DEVICES

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POTENTIOMETERS

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POTENTIOMETERS

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ENCODERS

A device used to convert linear

or rotational position information
into an electrical output signal.

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ENCODERS

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INDUSTRIAL APPLICATIONS of
ENCODERS

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RESOLVERS

 A resolver is a rotary
transformer that
produces an output
signal that is a
function of the rotor
position.

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SERVOMOTOR with RESOLVER

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VELOCITY FEEDBACK

 Tachometers:
Electrical output is proportional to rate of angular
rotation.
 Encoders, Resolvers, Potentiometers:
Number of pulses per time is proportional to rate
change of position.

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CNC CUTTERS

Turning center cutters

Machining center
cutters

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TURNING CENTER CUTTERS

Types of cutters used on CNC turning
centers
 Carbides (and other hard materials) insert
turning and boring tools
 Ceramics
 High Speed Steel (HSS) drills and taps

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STANDART INSERT SHAPES

 V – used for profiling, weakest
insert, 2 edges per side.
 D – somewhat stronger, used for
profiling when the angle allows it,
2 edges per side.
 T – commonly used for turning
because it has 3 edges per side.
 C – popular insert because the
same holder can be used for
turning and facing. 2 edges per
side.
 W – newest shape. Can turn and
face like the C, but 3 edges per
side.
 S – Very strong, but mostly used
for chamfering because it won’t
cut a square shoulder. 4 edges
per side.
 R – strongest insert but least
commonly used.

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TYPICAL TURNING,
THREADING and PARTING TOOLS

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MACHINING CENTER CUTTING TOOLS

 Most machining centers
use some form of HSS or
carbide insert endmill as
the basic cutting tool.
 Insert endmills cut many
times faster than HSS,
but the
 HSS endmills leave a
better finish when side
cutting.

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MACHINING CENTER CUTTING

TOOLS (cont’d)
 Facemills flatten large
surfaces quickly and with
an excellent finish. Notice
the engine block being
finished in one pass with
a large cutter.

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MACHINING CENTER CUTTING

TOOLS (cont’d)
 Ball endmills (both HSS
and insert) are used for a
variety of profiling
operations such as the
mold shown in the
picture.
 Slitting and side cutters
are used when deep,
narrow slots must be cut.

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MACHINING CENTER CUTTING

TOOLS (cont’d)
Drills, Taps, and
Reamers
 Common HSS tools such
as drills, taps, and
reamers are commonly
used on CNC machining
centers. Note that a spot
drill is used instead of a
centerdrill. Also, spiral
point or gun taps are
used for through holes
and spiral flute for blind
holes. Rarely are hand
taps used on a machining
center.
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TOOL HOLDERS
 All cutting tools must be held in a
holder that fits in the spindle. These
include end mill holders (shown),
collet holders, face mill adapters,
etc. Most machines in the USA use a
CAT taper which is a modified NST
30, 40, or 50 taper that uses a pull
stud and a groove in the flange. The
machine pulls on the pull stud to
hold the holder in the spindle, and
the groove in the flange gives the
automatic tool changer something to
hold onto. HSK tool holders were
designed a number of years ago as
an improvement to CAT tapers, but
they are gaining acceptance slowly.

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CNC PROGRAMMING

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CNC PROGRAMMING
 Offline programming linked to CAD programs.
 Conversational programming by the operator.
 MDI ~ Manual Data Input.
 Manual Control using jog buttons or `electronic
handwheel'.
 Word-Address Coding using standard G-codes
and M-codes.

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Basics of NC Part Programming:

During secondary motion, either the tool moves relative

to the workpiece or the workpiece moves relative to the
tool. In NC programming, it is always assumed that the
tool moves relative to the workpiece no matter what the
real situation is.

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The position of the tool is described by using a Cartesian

coordinate system. If (0,0,0) position can be described by
the operator, then it is called floating zero.

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In defining the motion of the tool from one point to

another, either absolute positioning mode or incremental
positioning mode can be used.

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1. Absolute positioning. In this mode, the desired target

position of the tool for a particular move is given relative
to the origin point of the program.

2. Incremental positioning. In this mode, the next target

position for the tool is given relative to the current tool
position.

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Structure of an NC Part Program:

Commands are input into the controller in units
called blocks or statements.

Block Format:

1. Fixed sequential format

2. Tab sequential format
3. Word address format

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EXAMPLE:
Assume that a drilling operation is to be
programmed as:

1. The tool is positioned at (25.4,12.5,0) by a rapid

movement.
2. The tool is then advanced -10 mm in the z direction at
a feed rate of 500 mm/min., with the flood coolant on.
3.The is then retracted back 10 mm at the rapid feed rate,
and the coolant is turned off.

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1. Fixed sequential format

0050 00 +0025400 +0012500 +0000000 0000 00
0060 01 +0025400 +0012500 -0010000 0500 08
0070 00 +0025400 +0012500 +0000000 0000 09

2. Tab sequential format

0050 TAB 00 TAB +0025400 TAB +0012500 TAB +0000000 TAB TAB
0060 TAB 01 TAB TAB TAB -0010000 TAB 0500 TAB 08
0070 TAB 00 TAB TAB TAB -0000000 TAB 0000 TAB 09

3. Word address format

N50 G00 X25400 Y125 Z0 F0
N60 G01 Z-10000 F500 M08
N70 G00 Z0 M09

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Modal commands: Commands issued in the NC program

that will stay in effect until it is changed by some other
command, like, feed rate selection, coolant selection, etc.

Nonmodal commands: Commands that are effective only

when issued and whose effects are lost for subsequent
commands, like, a dwell command which instructs the
tool to remain in a given configuration for a given amount
of time.

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CNC PROGRAMMING

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INFORMATION NEEDED by a CNC

1. Preparatory Information: units, incremental or absolute
positioning
2. Coordinates: X,Y,Z, RX,RY,RZ
3. Machining Parameters: Feed rate and spindle speed
4. Coolant Control: On/Off, Flood, Mist
5. Tool Control: Tool and tool parameters
6. Cycle Functions: Type of action required
7. Miscellaneous Control: Spindle on/off, direction of rotation,
stops for part movement
This information is conveyed to the machine through a set
of instructions arranged in a desired sequence – Program.

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BLOCK FORMAT
Sample Block
N135 G01 X1.0 Y1.0 Z0.125 F5

 Restrictions on CNC blocks

 Each may contain only one tool move
 Each may contain any number of non-tool move G-codes
 Each may contain only one feedrate
 Each may contain only one specified tool or spindle speed
 The block numbers should be sequential
 Both the program start flag and the program number must
be independent of all other commands (on separate
lines)
 The data within a block should follow the sequence shown
in the above sample block

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WORD-ADDRESS CODING
Example CNC Program
Each instruction to the machine
 N5 G90 G20 consists of a letter followed by a
 N10 M06 T3 number.
 N15 M03 S1250
 N20 G00 X1 Y1 Each letter is associated with a
 N25 Z0.1 specific type of action or piece of
 N30 G01 Z-0.125 F5 information needed by the
 N35 X3 Y2 F10 machine.
 N40 G00 Z1 Letters used in Codes
 N45 X0 Y0
 N50 M05 N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M
 N55 M30
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G & M Codes
Example CNC Program
 N5 G90 G20
• G-codes: Preparatory Functions
 N10 M06 T3
involve actual tool moves.
 N15 M03 S1250
 N20 G00 X1 Y1
• M-codes: Miscellaneous
 N25 Z0.1
Functions – involve actions
 N30 G01 Z-0.125 F5
necessary for machining (i.e.
 N35 X3 Y2 F10
spindle on/off, coolant on/off).
 N40 G00 Z1
 N45 X0 Y0
 N50 M05
 N55 M30

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G Codes
 G00 Rapid traverse  G40 Cutter compensation
 G01 Linear interpolation – cancel
 G02 Circular  G41 Cutter compensation
interpolation, – left
CW
 G42 Cutter
 G03 Circular compensation- right
interpolation, CCW
 G04 Dwell  G70 Inch format
 G08 Acceleration  G71 Metric format
 G09 Deceleration  G74 Full-circle
 G17 X-Y Plane programming off
 G18 Z-X Plane  G75 Full-circle
 G19 Y-Z Plane programming on
 G20 Inch Units (G70)  G80 Fixed-cycle cancel
 G21 Metric Units (G71)  G81-G89 Fixed cycles
 G90 Absolute dimensions
 G91 Incremental
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Modal G-Codes

 Most G-codes set the machine in a “mode”

which stays in effect until it is changed or
cancelled by another G-code. These
commands are called “modal”.

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Modal G-Code List

 G00 Rapid Transverse  G43 Tool length
 G01 Linear Interpolation compensation (plus)
 G02 Circular Interpolation,  G44 Tool length
CW compensation
 G03 Circular Interpolation, (minus)
CCW
 G49 Tool length
 G17 XY Plane compensation cancel
 G18 XZ Plane
 G80 Cancel canned cycles
 G19 YZ Plane
 G20/G70 Inch units
 G81 Drilling cycle
 G21/G71 Metric Units  G82 Counter boring cycle
 G40 Cutter compensation  G83 Deep hole drilling
cancel cycle
 G41 Cutter compensation  G90 Absolute positioning
left  G91 Incremental
 G42 Cutter compensation positioning
right
 G43 Tool length
compensation (plus)

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M Codes
 M00 Program stop
 M01 Optional program stop
 M02 Program end
 M03 Spindle on clockwise
 M04 Spindle on counterclockwise
 M05 Spindle stop
 M06 Tool change
 M08 Coolant on
 M09 Coolant off
 M10 Clamps on
 M11 Clamps off
 M30 Program stop, reset to start

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N Codes
 Gives an identifying number for each block of
information.

 It is generally good practice to increment each

block number by 5 or 10 to allow additional
blocks to be inserted if future changes are
required.

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X,Y, and Z Codes

X, Y, and Z codes are used to specify the
coordinate axis.
 Number following the code defines the
coordinate at the end of the move relative
to an incremental or absolute reference
point.

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I,J, and K Codes

 I, J, and K codes are used to specify the
coordinate axis when defining the center
of a circle.

 Number following the code defines the

respective coordinate for the center of the
circle.

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F,S, and T Codes

 F-code: used to specify the feed rate

 S-code: used to specify the spindle speed

 T-code: used to specify the tool

identification number associated with the
tool to be used in subsequent operations.

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Application of Some Codes

G01 Linear Interpolation
Format: N_ G01 X_ Y_ Z_ F_

 Linear Interpolation results in a straight

line feed move.

 Unless tool compensation is used, the

coordinates are associated with the
centerline of the tool.

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Application of Some Codes

G01 Linear Interpolation
 . As an example, for the motion that
occurs in x-y plane with the same
maximum speed for the x- and y-axis,
initial motion is at an angle of 45o to the
axes until motion in one of

 the axes is completed and then the

balance of the motion occurs in the other
axis. This is called point-to-point motion.

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Application of Some Codes

G01 Linear Interpolation

2 5

B C
2 0

1 5

1 0 P o s i t i o n i n g m o t i o n f r o m A t o C

N 1 0 G 0 0 X 3 0 0 0 0 Y 2 0 0 0 0 F 0
A
5

5 1 0 1 5 2 0 2 5 3 0

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Application of Some Codes

G01 Linear Interpolation

G01 is another preparatory function to specify

that the tool should be moved to a specified
location along a straight line path. It is referred
to as linear interpolation.

This function is typically used to specify

machining of straight features such as turning
a cylindrical surface in turning, cutting a slot in
milling, etc.
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Application of Some Codes

G01 Linear Interpolation
L i n e a r i n t e r p o l a t i o n f r o m A t o C
2 5 N 1 0 G 0 1 X 3 0 0 0 0 Y 2 0 0 0 0 F 2 5 0 0

C
2 0

1 5

1 0

A
5

5 1 0 1 5 2 0 2 5 3 0
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G01 Linear Interpolation

N10 G00 X1 Z1
Z N15 Z0.1
N20 G01 Z-0.125 F5
N25 X2 Z2 F10

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G02 Circular Interpolation

 G02 is also a preparatory function to
specify that the tool should be moved to
a specified location along a circular path in
a clockwise direction. In order to specify
the path to the MCU, the end point of the
arc and the location of the center of the
arc should be specified. Within the block in
which the G02 code is programmed, the
center of the arc is given by specifying its
location relative to the start of the arc.
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G02 Circular Interpolation (CW)

 The G02 command

requires an endpoint and
a radius in order to cut
the arc.
 I,J, and K are relative to
the start point.

N_ G02 X2 Y1 I0 J-1
F10
or
N_ G02 X2 Y1 R1
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G02 Circular Interpolation (CW)

C i r c u l a r i n t e r p o l a t i o n f r o m A t o B

a b o u t a c i r c l e c e n t e r e d a t C

N 1 0 G 0 2 X 2 0 0 0 0 Y 1 0 0 0 0

2 5 I 5 0 0 0 J 1 5 0 0 0 F 2 5 0 0

I = 5 A C
2 0

1 5
J = 1 5

1 0 B

C
5

5 1 0 1 5 2 0 2 5 3 0
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Canned Cycles
The sequence of some machining operations is may be
the same for any part and for any machine. For example,
drilling a hole involves the following steps:

Position the tool above the point where the hole will be
drilled

Set the correct spindle speed

Feed the tool into the workpiece at a controlled feed rate

to a predetermined depth

Retract the tool at a rapid rate to just above the point

where the hole started

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Some Commonly Used Canned Cycle

Code Function Down feed At bottom Retracti
on
G81 Drilling Continuous No action Rapid
feed
G82 Spot face, Continuous Dwell Rapid
counterbore feed
G83 Deep hole drilling Peck No action Rapid
G84 Tapping Continuous Reverse Feed
feed spindle rate
G85 Through boring(in Continuous No action Feed
& out) feed rate
G86 Through boring(in Continuous Stop Rapid
only) feed spindle
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G81 ILLUSTRATION

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Three Main parts of a CNC program

Part 1- Program Petup

 N5 G90 G21 (Absolute units, metric)

 N10 M06 T2 (Stop for tool change,

use tool # 2)
 N15 M03 S1200 (Turn the spindle on CW
to 1200 rpm)

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Three Main parts of a CNC program

Part 2- Chip Removal

 N20 G00 X1 Y1 (Rapid to X1,Y1 from origin
point)
 N25 Z0.125 (Rapid down to Z0.125)
 N30 G01 Z-0.125 F100 (Feed down to Z-0.125 at
100 mm/min)
 N35 G01 X2 Y2 (Feed diagonally to X2,Y2)
 N40 G00 Z1 (Rapid up to Z1)
 N45 X0 Y0 (Rapid to X0,Y0)

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Three Main parts of a CNC program

Part 3- System Shutdown

 N50 M05 (Turn the spindle off)

 N55 M00 (Program stop)

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EXAMPLE OPERATION on CNC MILLING

MACHINE

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G-CODE PROGRAM

 First pass : conventional

mill to a depth of 0.125
around edge profile. Tool
1 is a ½ inch dia. end
mill.

%
:1002
N5 G90 G20
N10 M06 T1
N15 M03 S1200
N20 G00 X0.125 Y0.125
N30 Z0.125
N35 G01 Z-0.125 F5
N40 X3.875
N45 Y4.125
N50 X0.125
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 Second pass: conventional

mill to a depth of 0.25
around edge profile.

N35 Z-0.250
N40 X3.875
N45 Y4.125
N50 X0.125
N55 Y0.125
N60 Z0.125

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 Third pass: conventional

mill to a depth of 0.125
around pocket profile.

N65 G00 X1.25 Y1.0

N70 G01 Z-0.125 F5
N75 X1.75
N80 Y2.5
N85 X1.25
N90 Y1.0
N95 Z0.125

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 Fourth pass: climb mill to a

depth of 0.125 across
remaining material.

N100 Y2.125
N105 X2.625
N110 Z0.125
N115 G00 X-5 Y-5 Z5
N120 M05
N125 M30

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Advanced features:

 Execution of the part of the program in a

rotated or mirrored position.
 Ability to scale the program and produce
larger or smaller programs.
 Three dimensional circular interpolation
which produces a helical shape.
 Parabolic and cubic interpolation.

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Program Loading:

 Through keyboard
 Through punched tape reader
 Through diskette drive
 Through RS 232 serial port
 Through network interface card

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Direct Numerical Control (DNC):

 A system in which a central computer

downloads the NC programs block by block
to many NC machine tools simultaneously
is called Direct Numerical Control (DNC)
system.

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Direct Numerical Control (DNC):

 This system used to work with the early NC

machine tools which can not read more than
a block of information at a time. The central
computer feed the program information one
block at a time. When the machine execute
the information, the next block of
information would be fed.

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Distributed Numerical Control (DNC):

 Distributed NC is known by the same acronym

as Direct Numerical Control (DNC). After the
introduction of CNC, the machine tools have had
the capability of storing large amount of
information. Therefore, there have been no need
to have drip feed information system, like,
Direct Numerical Control. Instead, Distributed
Numerical Control is introduced. In such a
system, a host computer communicate with
many CNC machine tools via networks and
download or upload programs.

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Distributed Numerical Control (DNC):

 With Distributed Numerical Control systems,

it is possible to monitor the activities in
individual CNC machine tools on host
computer.
 Therefore, better shop floor control can be
achieved.

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Computer Aided Part Programming:

 NC program preparation may be tedious and
difficult if the part to be machined has a
complex geometry. The main difficulty is to find
out the cutter locations during the machining.
Computers may be used to assist the
programmers in preparing the NC codes.

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Advantages of applying computer-aided part

programming include the following:

 It reduces the manual calculations involves in

determining the geometric characteristics of the part.
 It provides the cutter path simulation.
 It provides tool collision checking.
 It shortens the program preparation time.
 It makes the program preparation easier.

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 The Aerospace Industries Association sponsored the work

that led to the first part programming language,
developed in MIT in 1955.
 This was called: Automatically Programmed Tools (APT).
 APT is an English like simple programming language
which basically produce the Cutter Location (CL) data.
 Using the cutter location data, the program can generate
the actual NC codes by using a postprocessor .

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CAD/CAM Based Part Programming:

 The output of any CAD package include the geometric data

of the part to be machined. Therefore, many CAD/CAM
package can produce cutter location (CL) data to be used
for NC code generation.
 There is still to be a process planning module for a
workable NC code generation.
 Some of the CAD/CAM packages that have the NC code
generation capabilities are Computervision, CATIA,
CADAM, ProEngineer, MechanicalDesktop (Auto Desk).

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