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CNC

TECHNOLOGY

1
INTRODUCTION TO
CNC AND METAL
CUTTING

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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

5
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

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

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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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PROFIT increases as COST decreases
and as PRODUCTIVITY increases.

PRODUCTIVITY through AUTOMATION

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any means of helping
the workers to perform
their tasks more
efficiently
AUTOMATION

transfer of the skill of


the operator to the
machine

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Transferred Results
skill
muscle power engine driven First industrial
machine tools revolution
manipulating mechanization hard automation
skill
vision skill use of position increase of
transducers, accuracy, part
cameras recognition
brain power cnc machines, industrial second industrial
robots, soft
automation, revolution
computer control of
manufacturing
systems 26
COST = COST OF
MANUFACTURING AND
COST OF MATERIAL
HANDLING

EFFICIENCY OF PRODUCTIVITY =
MANUFACTURING AVERAGE OUTPUT PER
MAN-HOUR

PROFIT = INCOME - COST

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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

31
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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FUNDAMENTAL OF
METAL CUTTING

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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.

35
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
between tool and Secondary motion
workpiece

Cutting motion Feed motion

Cutting Feed rate


speed
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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 MULTIPOIN ABRASIVE
POINT T 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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BASIC COMPONENTS
OF CNC SYSTEMS

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machine control unit
position transducers

work holding device

tool holding device

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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


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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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MACHINE TOOL
AUTOMATION

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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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CONTROL
 Desired path (p, v, a)
 3-axis position control (encoder feedback)
 Velocity control (tachometer feedback)
 Torque control (current feedback)
 Path generator
 Linear interpolation
 Circular interpolation
 Complex path interpolation (contouring)
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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COMPONENTS OF
RECIRCULATING BALL SCREWS

 Ball screw
 Ball nut (anti-backlash)
 Ways
 Linear bearings
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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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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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DRIVE MOTORS
 DC servo motors
 AC servo motors
 Stepper motors
 Hydraulic motors
POSITION FEEDBACK
 Incremental encoder
 Quadrature
 Absolute encoder
 Resolver
 Tachometer
 No feedback (open
loop)
POTENTIOMETERS

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POTENTIOMETERS

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CNC Programming
 Manual
 Write code directly
 Computer-assisted
 Draw cutter path
 CAD/CAM
 Draw the part
 Cutter path is generated
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 MACHINES
CUTTING TOOLS (CUTTERS)

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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.

104
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
 N5 G90 G20 Each instruction to the machine
 N10 M06 T3 consists of a letter followed by a
 N15 M03 S1250 number.
 N20 G00 X1 Y1
 N25 Z0.1
Each letter is associated with a
 N30 G01 Z-0.125 F5
 N35 X3 Y2 F10 specific type of action or piece of
 N40 G00 Z1 information needed by the machine.
 N45 X0 Y0 Letters used in Codes
 N50 M05
 N55 M30 N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M

106
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
 N35 X3 Y2 F10 necessary for machining (i.e.
 N40 G00 Z1 spindle on/off, coolant on/off).
 N45 X0 Y0
 N50 M05
 N55 M30

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

108
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, CW
 G03 Circular Interpolation,  G44 Tool length
CCW compensation (minus)
 G17 XY Plane  G49 Tool length
 G18 XZ Plane
 G19 YZ Plane
compensation cancel
 G20/G70 Inch units  G80 Cancel canned cycles
 G21/G71 Metric Units  G81 Drilling cycle
 G40 Cutter compensation
cancel  G82 Counter boring cycle
 G41 Cutter compensation left  G83 Deep hole drilling cycle
 G42 Cutter compensation right
 G43 Tool length compensation
 G90 Absolute positioning
(plus)  G91 Incremental positioning

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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

111
N Codes
 Gives an identifying number for each block
of information.

 It is generally good practice toincrement


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

112
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.

113
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.

114
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.

115
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.

116
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.

117
Application of Some Codes
G01 Linear Interpolation

25
B C
20

15

10 Positioning motion from A to C


A N10 G00 X30000 Y20000 F0
5

5 10 15 20 25 30
118
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.

119
Application of Some Codes
G01 Linear Interpolation

Linear interpolation from A to C


25 N10 G01 X30000 Y20000 F2500
C
20

15

10
A
5

5 10 15 20 25 30
120
G01 Linear Interpolation

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

121
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.

122
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

123
G02 Circular Interpolation (CW)
Circular interpolation from A to B
about a circle centered at C
N10 G02 X20000 Y10000
25 I5000 J15000 F2500
I=5 A C
20

15
J=15
10 B
C
5

5 10 15 20 25 30 124
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

125
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


126
G81 ILLUSTRATION

127
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)

128
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)

129
Three Main parts of a CNC
program

Part 3- System Shutdown


 N50 M05 (Turn the spindle off)

 N55 M00 (Program stop)

130
EXAMPLE OPERATION on CNC
MILLING MACHINE

131
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
N55 Y0.125

132
 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

133
 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

134
 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

135
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.

136
Program Loading:

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

137
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.

138
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.

139
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.

140
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.

141
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.

142
Advantages of applying computer-aided part
programming include the following:

 1. 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.

143
 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 .

144
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).

145

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