CNC

TECHNOLOGY
1

INTRODUCTION TO
CNC AND METAL
CUTTING

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.
3

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.

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

CNC TURNING

CNC MILLING

CNC LASER CUTTING

CNC PLASMA CUTTING

10

CNC PRESS

11

CNC RAPID PROTOTYPING

12

INDUSTRIES MOST AFFECTED

by CNC
Aerospace

Machinery
Electrical
Fabrication
Automotive
Instrumentation
Mold

making
13

SAMPLE PRODUCTS
OF
CNC MANUFACTURING

14

AUTOMOTIVE INDUSTRY
Engine Block

15

AUTOMOTIVE INDUSTRY(Contd)
Different Products

16

AEROSPACE INDUSTRY
Aircraft Turbine Machined by
5-Axis CNC Milling Machine

17

CNC MOLD MAKING

18

ELECTRONIC INDUSTRY

19

RAPID PROTOTYPING
PRODUCTS

20

ADVANTAGES OF CNC

21

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.
22

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.

23

PROFIT increases as COST decreases

and as PRODUCTIVITY increases.

PRODUCTIVITY through AUTOMATION

24

AUTOMATION

any means of helping

the workers to perform
their tasks more
efficiently

transfer of the skill of

the operator to the
machine
25

Transferred
skill
muscle power
manipulating
skill
vision skill

brain power

Results
engine driven First industrial
machine tools
revolution
mechanization hard automation
use of position
transducers,
cameras
cnc machines, industrial
robots, soft
automation,
computer control of
manufacturing
systems

increase of
accuracy, part
recognition
second industrial
revolution
26

COST = COST OF
MANUFACTURING AND
COST OF MATERIAL
HANDLING

EFFICIENCY OF
MANUFACTURING

PRODUCTIVITY =
AVERAGE OUTPUT PER
MAN-HOUR
PROFIT = INCOME - COST

27

ADVANTAGES of CNC
Quality

Parts are more accurate.

Parts are more repeatable.
Less waste due to scrap.

28

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.

29

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.

30

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

32

FUNDAMENTAL OF
METAL CUTTING

33

The metal cutting operations (also

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

34

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 workpiececutting tool positional relationship in
such a way as to achieve a desired
geometric shape of the workpiece
with sufficient dimensional
accuracy.
36

Machine tool provides:

work holding
tool holding
relative motion between tool
and workpiece
primary motion
secondary motion
37

Primary motion

Relative motion
between tool and
workpiece

Cutting motion

Cutting
speed

Secondary motion

Feed motion
Feed rate
38

CLASSIFICATION OF THE CHIP REMOVING

METHODS ACCORDING TO THE RELATIVE MOTION

39

CLASSIFICATION OF MACHINE TOOLS

THOSE USING
SINGLE
POINT
TOOLS
lathes
shapers
planers
boring m/cs
etc.

THOSE USING
MULTIPOIN
T TOOLS

THOSE USING
ABRASIVE
TOOLS

drilling m/cs
milling m/cs
broaching m/cs
hobbing m/cs
etc.

grinding m/cs
honing m/cs
etc.

40

BASIC COMPONENTS
OF CNC SYSTEMS

41

m a c h i n e
p o s i t i o n

c o n t r o l

t r a n s d u c e r s

w o r k

t o o l

h o l d i n g

u n i t

h o l d i n g

d e v i c e

d e v i c e

42

ISO MACHINE TOOL AXIS DEFINITION

43

ISO MACHINE TOOL AXES DEFINITIONS

AXIS
Z

MACHINE TOOL WITH SPINDLE

MACHINE TOOL WITH

NO SPINDLE

axis of spindle,
(+Z) as tool goes away from the work piece

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

MACHINE
TOOL WITH
ROTATING
WORKPIECE

MACHINE TOOL WITH

ROTATING TOOL

HORIZONT
AL AXIS

VERTICAL
AXIS

horizontal
and parallel
to work
holding
surface,
(+X) to the
right when
viewed
from
spindle
towards
work piece

horizontal
and parallel
to the work
holding
surface,
(+X) to the
right when
viewed
from
spindle
towards
column

radial and
parallel to
cross slide,
(+X) when
tool goes away
from the axis
of spindle

apply right hand rules

parallel to and positive in

the principal direction of
cutting (primary motion)

44

RIGHT HAND RULE

Vertical Machine

Horizontal Machine

45

STANDARD LATHE
COORDINATE SYSTEM

46

STANDARD MILLING MACHINE

COORDINATE SYSTEM

47

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.
48

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.

49

MACHINE TOOL
AUTOMATION

50

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
51

NC SYSTEM ELEMENTS

52

OPERATIONAL FEATURES of
CNC MACHINES

53

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
54

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.

55

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
56

TYPES of CNC CONTROL

SYSTEMS
Open-loop

control
Closed-loop control

57

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

58

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
59

CONTROL
Desired

3-axis position control (encoder feedback)

Velocity control (tachometer feedback)
Torque control (current feedback)

Path

path (p, v, a)

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.
61

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 .
62

STEPPING MOTORS

63

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

64

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.
65

COMPONENTS OF
RECIRCULATING BALL SCREWS

Ball screw
Ball nut (anti-backlash)
Ways
Linear bearings

67

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.

68

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.
69

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.
70

CNC MACHINES FEEDBACK

DEVICES

71

ENCODERS
A

device used to convert linear or

rotational position information into
an electrical output signal.

72

ENCODERS

73

INDUSTRIAL APPLICATIONS of
ENCODERS

74

RESOLVERS

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

75

SERVOMOTOR with
RESOLVER

76

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

79

POTENTIOMETERS

80

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.

82

CNC MACHINES
CUTTING TOOLS (CUTTERS)

83

CNC CUTTERS

Turning

center cutters
Machining center cutters

84

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

85

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 wont
cut a square shoulder. 4 edges
per side.
R strongest insert but least
commonly used.

86

TYPICAL TURNING,
THREADING and PARTING
TOOLS

87

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.

88

MACHINING CENTER CUTTING

TOOLS (contd)

Facemills flatten large

surfaces quickly and
with an excellent
finish. Notice the
engine block being
finished in one pass
with a large cutter.

89

MACHINING CENTER CUTTING

TOOLS (contd)

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.

90

MACHINING CENTER CUTTING

TOOLS (contd)

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.

91

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.

92

CNC PROGRAMMING

93

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.

94

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.
95

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.

96

In defining the motion of the tool

from one point to another,
either
absolute positioning mode or
incremental positioning mode
can be used.

97

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.

98

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
99

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.

100

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
101

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.
102

CNC PROGRAMMING

103

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 Gcodes
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

105

WORD-ADDRESS CODING
Example CNC Program

N5 G90 G20
N10 M06 T3
N15 M03 S1250
N20 G00 X1 Y1
N25 Z0.1
N30 G01 Z-0.125 F5
N35 X3 Y2 F10
N40 G00 Z1
N45 X0 Y0
N50 M05
N55 M30

Each instruction to the machine

consists of a letter followed by a
number.
Each letter is associated with a
specific type of action or piece of
information needed by the machine.
Letters used in Codes

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
N10 M06 T3
N15 M03 S1250
N20 G00 X1 Y1
N25 Z0.1
N30 G01 Z-0.125 F5
N35 X3 Y2 F10
N40 G00 Z1
N45 X0 Y0
N50 M05
N55 M30

G-codes: Preparatory Functions

involve actual tool moves.
M-codes: Miscellaneous
Functions involve actions
necessary for machining (i.e.
spindle on/off, coolant on/off).

107

G Codes

G00 Rapid traverse

G01 Linear interpolation
G02 Circular interpolation,
CW
G03 Circular interpolation,
CCW
G04 Dwell
G08 Acceleration
G09 Deceleration
G17 X-Y Plane
G18 Z-X Plane
G19 Y-Z Plane
G20 Inch Units (G70)
G21 Metric Units (G71)

G40 Cutter compensation

cancel
G41 Cutter compensation
left
G42 Cutter compensationright
G70 Inch format
G71 Metric format
G74 Full-circle programming
off
G75 Full-circle programming
on
G80 Fixed-cycle cancel
G81-G89 Fixed cycles
G90 Absolute dimensions
G91 Incremental dimensions
108

Modal G-Codes

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.

Most

109

Modal G-Code List

G00
G01
G02
G03

Rapid Transverse
Linear Interpolation
Circular Interpolation, CW
Circular Interpolation,
CCW
G17 XY Plane
G18 XZ Plane
G19 YZ Plane
G20/G70
Inch units
G21/G71
Metric Units
G40 Cutter compensation
cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation
(plus)

G43 Tool length

compensation
(plus)
G44 Tool length
compensation
(minus)
G49 Tool length
compensation
cancel
G80 Cancel canned cycles
G81 Drilling cycle
G82 Counter boring cycle
G83 Deep hole drilling cycle
G90 Absolute positioning
G91 Incremental positioning

110

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 to increment

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 xy plane with the same maximum speed for the xand 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
2 5

2 0

1 5

1 0

P o s i t i o n i n g

N 1 0

G 0 0

1 5

2 0

m o t i o n

X 3 0 0 0 0

f r o m

Y 2 0 0 0 0

t o

F 0

1 0

2 5

3 0

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
L i n e a r
2 5

N 1 0

i n t e r p o l a t i o n

G 0 1

X 3 0 0 0 0

Y 2 0 0 0 0

f r o m

t o

F 2 5 0 0
C

2 0

1 5

1 0

A
5

1 0

1 5

2 0

2 5

3 0

120

G01 Linear Interpolation

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

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)

C i r c u l a r
a b o u t
N 1 0
2 5

i n t e r p o l a t i o n

f r o m

c i r c l e

c e n t e r e d

G 0 2

X 2 0 0 0 0

Y 1 0 0 0 0

I 5 0 0 0

I = 5

J 1 5 0 0 0

a t

t o

F 2 5 0 0

2 0

1 5
J = 1 5

1 0

B
C

1 0

1 5

2 0

2 5

3 0

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

G81

Drilling

Continuous
feed

No action

Retracti
on
Rapid

G82

Continuous
feed
Peck

Dwell

Rapid

G83

Spot face,
counterbore
Deep hole drilling

No action

Rapid

G84

Tapping

Reverse
spindle
No action

Feed
rate
Feed
rate
Rapid

G85
G86

Continuous
feed
Through boring(in Continuous
& out)
feed
Through boring(in Continuous
only)
feed

Stop
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

N15 M03 S1200

(Stop for tool change, use

tool # 2)
(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 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