Programming

Programming
For the Fanuc 0T controller

Axes convention

X Axis

Z Axis

Absolute and Incremental co-ordinates

In the absolute programming, the end point of a motion is programmed with reference to the program zero point. In incremental programming, the end point is specified with reference to the current tool position. X 50
N2

20 0,0 30 50

N1

Absolute traverse to N1, then to N2 X20.0 Z50.0 X50.0 Z30.0 Absolute traverse to N1, incremental to N2 X20.0 Z50.0 U30.0 W-20.0

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Programming
For the Fanuc 0M controller

Axes convention
The tool can be moved to any position in a 3 dimensional cartesian co-ordinate system. The Z axis is along the spindle axis. The X and Y axes are perpendicular to Z.

VMC (Vertical Machining Center)

+ Z + X -X + -Y -Z +X +Z +Y

Y -

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HMC (Horizontal Machining Center)

+ Y X + Z +

Part X Machine table

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List of G-codes
G-code G00 G01 G02 G03 G04 G20 G21 G28 G30 G40 G41 G42 G43 G52 G54 G55 G56 G57 G58 G59 G74 G76 G80 G81 G82 G83 G84 G85 G86 G87 G90 G91 G94 G95 G98 G99 Function Positioning rapid traverse Linear interpolation (feed) Circular interpolation CW Circular interpolation CCW Dwell Inch unit Metric unit Automatic zero return 2nd reference point return Tool nose radius compensation cancel Tool nose radius compensation left Tool nose radius compensation right Tool length compensation Local co-ordinate system Work co-ordinate system 1 selection Work co-ordinate system 2 selection Work co-ordinate system 3 selection Work co-ordinate system 4 selection Work co-ordinate system 5 selection Work co-ordinate system 6 selection Left hand tapping cycle Fine boring cycle Canned cycle cancel Drilling cycle Drilling cycle with dwell Peck drilling cycle / deep drill Tapping cycle Boring / Reaming cycle Boring cycle Back boring cycle

Absolute command Incremental command

Feed per minute Feed per revolution Return to initial point in canned cycle Return to R point in canned cycle

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List of M codes
M codes vary from machine to machine depending on the functions available on it. They are decided by the manufacturer of the machine. The M codes listed below are the common ones.
M-codes M00 M01 M02 M03 M04 M05 M06 M07 M08 M09 M19 M30 M98 M99 Function Optional program stop automatic Optional program stop request Program end Spindle ON clock wise (CW) Spindle ON counter clock wise (CCW) Spindle stop Tool change Mist coolant ON (coolant 1 ON) Flood coolant ON (coolant 2 ON) Coolant OFF Spindle orientation End of program, Reset to start Sub program call Sub program end

There are other M-codes for functions like gear change, pallet change, pallet clamp / unclamp, door open / close etc.

Absolute and Incremental co-ordinates

In the absolute programming , the end point of a motion is programmed with reference to the program zero point. In incremental programming, the end point is specified with reference to the current tool position.

Y 50
N2

20 0,0
Absolute traverse to N1, then to N2 G90 X20.0 Z50.0 X50.0 Z30.0 Absolute traverse to N1, incremental to N2 G90 X20.0 Z50.0 G91 X-20. Y30

N1

30

50

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G00 Rapid traverse

When the tool being positioned at a point preparatory to a cutting motion, to save time it is moved along a straight line at Rapid traverse, at a fixed traverse rate which is pre-programmed into the machine's control system. Typical rapid traverse rates are 10 to 25 m /min., but can be as high as 80 m/min. Format N_ G00 X__ Y__Z__

G01 Linear interpolation (feed traverse)

The tool moves along a straight line in one or two axis simultaneously at a programmed linear speed, the feed rate. Format N__ G01 X__ Y__Z__ F__

Feed

Feed

Part Part

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G02/03 Circular interpolation

Format
N__ G02/03 X__ Y__Z__ I__ J__K__ F__ OR N__ G02/03 X__ Y__Z__ R__ F__ G02 moves along a CW arc G03 moves along a CCW arc using the arc center using the arc radius

Arc center
The arc center is specified by addresses I, J and K. I, J and K are the X, Y and Z co-ordinates of the arc center with reference to the arc start point.
Y
Arc start Arc end -I -J Arc center

I = X coord. of center - X coord. of start point J = Y coord. of center - Y coord. of start point K = Z coord. of center - Z coord. of start point I, J and K must be written with their signs.

Arc radius

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The radius is specified with address R.

Arc start

Arc end

Arc radius

Arc center

Block format
N__ G02 X__Y__ Z__ R__ F__ N__ G03 X__Y__ Z__ R__ F__

Cutter radius compensation (CRC)

G40 G41 G42 Tool nose radius compensation Cancel Tool nose radius compensation Left Tool nose radius compensation Right

G41

G41

G42

G42

Block format

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N__ G01 G41/42 X__ Y__ D__ F__ Feed rate mm/min CRC offset number CRC start co-ordinates absolute CRC command code Linear interpolation command code

Necessity of using CRC

Difficult to calculate cutter center co-ordinates If cutter center co-ordinates are used Same diameter of cutter is required to be used Cutter wear can not compensated

Program Zero

Tool length compensation (G43)

Different tools of different lengths are used in machining any part. The lengths of the tools are not considered in the part program. They are entered in the machines memory, and are considered automatically for each motion in the program depending on the tool that is being used. The tool lengths in the Z direction are called the Tool length offsets.

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Gauge line

Length offset

Length offset

Length offset

Length offset

Face milling cutter

T-slot milling cutter

Boring tool

Back boring tool

Part

Setting work co-ordinate system (G54 - G59)

G54 G55 G56 G57 G58 G59
Work co-ordinate system 1 selection Work co-ordinate system 2 selection Work co-ordinate system 3 selection Work co-ordinate system 4 selection Work co-ordinate system 5 selection Work co-ordinate system 6 selection

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Work co-ordinate system 3 selection Work co-ordinate system 1 selection

Work co-ordinate system 2 selection

Machine table

Work co-ordinate system 4 selection

Work co-ordinate system 6 selection Work co-ordinate system 5 selection

Canned cycles
Canned or fixed cycles are programming aids that simplify programming. Canned cycles combine many programming operations and are designed to shorten the program length, minimize mathematical calculations, and use minimal tool motions. Examples : drilling, peck drilling, tapping, boring, back spot facing. G81 G82 G83 G84 G85 G86 G87 G74 G76 Drilling cycle Drilling cycle with dwell (Counter bore cycle) Peck drilling cycle / deep drill Right hand tapping cycle Boring / Reaming cycle Boring cycle Back boring cycle Left hand tapping cycle Fine boring cycle

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Drilling cycle (G81)

With G98 return to initial point Initial point Rapid Feed

With G99 return to R point Rapid Feed

R point / Safe height

R point / Safe height

Format
N__ G98/99 G81 R__ Z__ F__ Infeed feed rate mm/min Final depth Safe height / R point Drilling cycle code Return position code Block number

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Counter bore cycle (G82)

With G98 return to initial point Initial point Rapid Feed With G99 return to R point Rapid Feed

R point / Safe height

R point / Safe height

Dwell at bottom

Dwell at bottom

Format
N__ G98/99 G82 R__ Z__ P__ F__ Infeed feed rate mm/min Dwell at bottom Final depth Safe height / R point Counter bore drilling cycle code Return position code Block number

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Peck drill cycle (G83)

With G98 return to initial point Initial point Rapid Feed

Safe height / R point Peck depth

Final depth

With G99 return to R point Initial point Rapid Feed

Safe height / R point Peck depth

Final depth

Format
N__ G98/99 G83 R__ Z__ Q__ F__ Infeed feed rate mm/min Peck depth Final depth Safe height / R point Peck drilling cycle code Return position code Block number

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Tapping cycle (G84)

Right hand tapping

With G98 return to initial point Initial point Rapid Feed

With G99 return to R point Initial point Rapid Feed

R point / Safe height Spindle CW Retract feed rate equals infeed feed rate Final depth Spindle CCW

R point / Safe height Spindle CW Retract feed rate equals infeed feed rate Final depth Spindle CCW

Feedrate = Spindle RPM x Pitch

Format
N__ G98/99 G84 R__ Z__ F__ Infeed / retract feed rate mm/min Final depth Safe height / R point Right hand tapping cycle code Return position code Block number

Spindle direction in RH tapping CW during infeed CCW during outfeed

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Reaming cycle (G85)

With G98 return to initial point Initial point Rapid Feed With G98 return to R point Initial point Rapid Feed

R point / Safe height

R point / Safe height

Final depth

Final depth

Format
N__ G98/99 G85 R__ Z__ F__ Infeed / retract feed rate mm/min Final depth Safe height / R point Reaming cycle code Return position code Block number

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Boring cycle (G86)

With G98 return to initial point Initial point Rapid Feed With G99 return to R point Rapid Feed

Spindle CW R point / Safe height

Spindle CW R point / Safe height

Final depth

Final depth

Spindle stop

Spindle stop

Format
N__ G98/99 G86 R__ Z__ F__ Infeed feed rate mm/min Final depth Safe height / R point Boring cycle code Return position code Block number

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Back boring cycle (G87)

Spindle orientation

Initial point Bore axis

Lateral shift

Final depth Spindle CW Safe height / R point

Format
N__ G98 G87 R__ Z__ Q__ F__ Infeed feed rate mm/min Lateral shift Final depth Safe height / R point Back boring cycle code Return position code Block number

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Tapping cycle (G74)

Left hand tapping

With G98 return initial point Initial point Rapid Feed

With G99 return R point Initial point Rapid Feed

R point / Safe height Spindle CCW Retract feed rate equals infeed feed rate Final depth Spindle CW

R point / Safe height Spindle CCW Retract feed rate equals infeed feed rate Final depth Spindle CW

Feedrate = Spindle RPM x Pitch

Format
N__ G98/99 G74 R__ Z__ F__ Infeed / retract feed rate mm/min Final depth Safe height / R point Left hand tapping cycle code Return position code Block number

Spindle direction in LH tapping CCW during infeed CW during outfeed

Fine boring cycle (G76)

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Fine boring cycle (G76)

With G98 return to initial point Initial point Rapid Feed With G99 return to R point Initial point Rapid Feed

Lateral shift

Lateral shift

Spindle CW R point / Safe height

Spindle CW R point / Safe height

Final depth Dwell at bottom Lateral shift Spindle Orientation Dwell at bottom

Final depth

Lateral shift Spindle Orientation

Format
N__ G98 G76 R__ Z__ Q__ F__ Infeed feed rate mm/min Lateral shift Final depth Safe height / R point Fine boring cycle code Return position code Block number

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Verifying NC programs
Safety priorities
Safety priorities must be followed when verifying programs.

Operator safety - priority 1 Safety of the person operating the machine Machine tool safety - priority 2 Prevention of damage to the machine Workpiece safety - priority 3 Prevention of part rejection

Typical errors
Syntax errors Errors which prevent the machine controller from executing a command. E.g., writing G101 instead of G01 Motion errors Machine does not generate an error, so these are difficult to diagnose. E.g., Writing X instead of Z; wrong co-ordinates; reversing CW and CCW commands; improper incremental/absolute mode selection. Omission errors Omitting decimal points, forgetting to program feed rates, forgetting to turn on the coolant Setup errors Wrongly measured work offset and tool offsets, or correct measurement and wrong entry

Program verification procedures

A new program is checked by executing it in some or all of the verification modes.

Dry run with Machine lock Used for checking syntax errors. Motion errors are not checked.

Set Machine lock ON and Dry run ON. Set feed rate override switch to maximum to execute the cycle fast. The spindle rotates, the turret indexes and the display changes as per program, but axes do not move. Tool and work offsets need not be set.

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Dry run with air cutting Used for checking motion errors and correctness of spindle direction. Since execution is at dry run feed, difference between rapid and feed motions is not known. Collisions cannot be checked. Set the tool offsets. Set the work offset so that all motions occur away from work holding devices like the chuck.. Do not load a part. Set Machine lock OFF and Dry run ON. All machine functions and motions are active. Set feed rate override switch to minimum for safety. Normal cycle with air cutting Used for checking collisions. Set the tool offsets. Set the work offset so that all motions occur away from work holding devices like the chuck.. Do not load a part. Set all functions for normal machine execution. For safety, when in doubt set the feed rate override switch to minimum. Carefully watch for motions which result in tool colliding with the part or work holding device. Single block execution Used for checking motion errors and part dimensional accuracy. Set the work offset normally, and load a part. Set the tool offsets to leave excess stock on the part. Set all functions for normal machine execution. For safety, when in doubt set the feed rate override switch to minimum. Check the Distance to go value to detect potential motion errors. Check all dimensions. For critical dimensions alter the tool offsets and rerun the tool again to check whether the dimension is within tolerance. Repeat till tolerance is achieved.

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Radius and diameter programming

X co-ordinates can be Radius or Diameter values.
100 50 B Dia 100 Dia 50 A

Tool traverse from A to B in Radius mode N2 X25. N3 Z-50. N4 X50. N5 Z-100.

Tool traverse from A to B in Diameter mode N2 X50. N3 Z-50. N4 X100. N5 Z-100.

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List of G-codes
G-code G00 G01 G02 G03 G04 G20 G21 G28 G30 G32 / G33 G40 G41 G42 G50 / G92 G70 G71 G72 G73 G74 G75 G76 G94 / G98 G95 / G99 G96 G97 Function Positioning rapid traverse Linear interpolation (feed) Circular interpolation CW Circular interpolation CCW Dwell Inch unit Metric unit Automatic zero return 2nd reference point return Thread cutting (single motion) Tool nose radius compensation cancel Tool nose radius compensation left Tool nose radius compensation right Local co-ordinate system setting, max. spindle speed setting Finishing cycle Stock removal in turning Stock removal in facing Pattern repeating Peck drilling on Z axis / Face grooving Peck drilling on X axis / Int-Ext grooving Multiple threading cycle Feed per minute Feed per revolution Constant surface speed control Constant surface speed control cancel

List of M codes
M codes vary from machine to machine depending on the functions available on it and the manufacturer of the machine decides them. The M codes listed below are the common ones.
M-codes M00 M01 M02 M03 M04 M05 M06 M07 M08 M09 M30 M98 M99 Function Optional program stop automatic Optional program stop request Program end Spindle ON clock wise (CW) Spindle ON counter clock wise (CCW) Spindle stop Tool change Mist coolant ON (coolant 1 ON) Flood coolant ON (coolant 2 ON) Coolant OFF End of program, Reset to start Sub program call Sub program end

There are other M-codes for functions like gear change, tail stock quill in/out, chuck clamp/unclamp, chip conveyor forward/backward, door open / close etc.

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G00 Rapid traverse

When the tool being positioned at a point preparatory to a cutting motion, to save time it is moved along a straight line at Rapid traverse, at a fixed traverse rate which is pre-programmed into the machine's control system. Typical rapid traverse rates are 10 to 25 m /min., but can be as high as 80 m/min. Format N_ G00 X_ Z_

Rapid traverse

G01 Linear interpolation (feed traverse)

The tool moves along a straight line in one or two axis simultaneously at a programmed linear speed, the feed rate. Format N__ G01 X__ Z__ F__

Feed motion

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G02/03 Circular interpolation

CW arc

CCW arc

Format
N__ G02/03 X__ Z__ I__ K__ F__ OR N__ G02/03 X__ Z__ R__ F__ G02 moves along a CW arc G03 moves along a CCW arc using the arc center using the arc radius

Arc center
The arc center is specified by addresses I and K. I and K are the X and Z co-ordinates of the arc center with reference to the arc start point. X
Arc start Arc end -K -I Arc center

Z I =(X coord. of center - X coord. of start point)/2 K = Z coord. of center - Z coord. of start point I and K must be written with their signs.

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Arc radius
The radius is specified with address R.
Arc start

Arc end

Arc radius

Arc center

N__ G02 X__ Z__ R__ F__ N__ G03 X__ Z__ R__ F__ If the radius is used, only arcs of less than 180 deg. can be programmed in a block. An arc with included angle greater than 180 deg. must be specified in two blocks.

Tool nose radius compensation

G40 G41 G42 Tool nose radius compensation Cancel Tool nose radius compensation Left Tool nose radius compensation Right

Right side G42 Left side G41

Right side G42 Left side G41

X axis

Z axis

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Theoretical tool tip (TTT)

The Theoretical Tool Tip is the point on the tool that is used as the reference point for determining tool offsets. When a motion is commanded, the TTT point on the tool moves to the commanded point. The path of the TTT point (point A in the figure) normally will not match with the co-ordinates in the program. To get an accurate contour during machining, the TTT point must move in such a manner that the nose radius is tangential to the contour.

Effect of tool nose radius on the part

1. If tool nose radius compensation is not used for the motion from P1 to P2, excess cutting occurs as shown in the figure.

2. If tool nose radius compensation is not used for motion from P2 to P3, material is left out as shown in the figure.

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Direction of immaginary tool nose

Imaginary tool nose number (Type No) must be set in advance (before tool index) as well as offset values. Z X Z X

Type No. 1

Type No. 2

Type No. 3

Type No. 4

Z Z X Z X X

Type No. 5

X Z

Type No. 6

Z X

Type No. 7
Z

Type No. 8

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The direction of the imaginary tool nose viewed from the tool nose center is determined by the direction of the tool during cutting.

Internal / External tools

3
Neutral tools

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Thread cutting motion G32

G32

Thread cutting is done by moving the tool along the thread repeatedly at different depths tiil the final thread profile is formed. Each cut must start at the same angular position on the part. The spindle has an encoder, which generates a pulse at exactly the same angular position in every revolution. When a threading motion is programmed, the linear motion of the tool starts when this pulse is detected. This ensures that every cut starts at the same angular position. Thread cutting must be done at constant spindle speed. Block format N__ G32 X__ Z__ F__ X, Z are the end point of the thread and F is the pitch of the thread. The controller calculates feed rate through the following relationship Feed rate = Pitch x Spindle speed Each threading cut involves 4 motions: 1 threading motion and 3 rapid traverse motions. Since a thread normally requires multiple cuts, G32 results in a long program and is not normally used. The G76 canned cycle is normally used for threading.

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Canned cycles
A canned cycle simplifies a program by using a few blocks containing G-codes functions to specify the machining operations usually specified in several blocks.

Turning Cycle - G71

Format G71 U (d) R (e) G71 P (n) Q(n) U(u) W(w) F(f) S(s) T(t) N (n) _ _ _ _ _______ _______ N (n)_ _ _ _ d = Depth of cut e = Retract amount n = Number of the first block of the shape n = Number of the last last block of the shape u = Finishing allowance in X w =Finishing allowance in Z f = Feed rate s = Spimdle speed t = Tool number

Facing Cycle - G72

Format G71 U (d) R (e) G71 P (n) Q(n) U(u) W(w) F(f) S(s) T(t) N (n) _ _ _ _ _______ _______ N (n) _ _ _ _ d = Depth of cut e = Retract amount n = Number of the first block of the shape n = Number of the last last block of the shape u = Finishing allowance in X w =Finishing allowance in Z f = Feed rate s = Spindle speed t = Tool number

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Multipass Turning Cycle - G73

Format G73 U (i) W (k) R (d) G73 P (n) Q (n) U (u) W (w) F (f) S(s) T (t) N (n)_ _ _ _ _ ________ ________ N (n)_ _ _ _ _ i = Relief in the X axes direction k = Relief in the Z axis direction d = Number of cuts n = Number of first block of the shape n = Number of the last block of the shape u = Finishing allowance in X w = Finishing allowance in Z f = Feed rate s = Spimdle speed t = Tool number

Axial Drilling Cycle -G74

Format G74R (e) G74X (U)_ Z (W)_ P(i) Q (k) R(d) F(f) e = Retract amount X = X component of point B U = Incremental amount from A to B Z = Z component of point C W = Increment amount from A to C i = Movement amount in X direction k = Depth of cut in Z direction d = Relief Amount of the tool at the cutting bottom f = Feed rate

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Radial Grooving Cycle - G75

Format G75R (e) G75X (U)_ Z (W)_ P(i) Q (k) R(d) F(f) e = Retract amount X = X component of point B U = Incremental amount from A to B Z = Z component of point C W = Increment amount from A to C i = Movement amount in X direction k = Depth of cut in Z direction d = Relief Amount of the tool at the cutting bottom f = Feed rate

Thread Cutting Cycle - G76

G76p (m) (r) (a) (d min) R (d) G76X (u) Z (W)_ R(i) P (k) Q(d) F(L) Format m = No.of idle passes r = Chamfering amount a = Angle of tool tip d min = Minimum thread depth d = Finishing Allowance i = Taper value k = Height of thread d = Depth of cut in first cut L = Lead of thread

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Verifying NC programs
Safety priorities
Safety priorities must be followed when verifying programs. Operator safety - priority 1 Safety of the person operating the machine Machine tool safety - priority 2 Prevention of damage to the machine Workpiece safety - priority 3 Prevention of part rejection

Typical errors
Syntax errors This prevents the machine controller from executing a command. E.g., writing G101 instead of G01 Motion errors Machine does not generate an error, so these are difficult to diagnose. E.g., Writing X instead of Z; wrong co-ordinates; reversing CW and CCW commands; improper incremental/absolute mode selection. Omission errors Omitting decimal points, forgetting to program feed rates, forgetting to turn on the coolant Setup errors Wrongly measured work offset and tool offsets, or correct measurement and wrong entry

Program verification procedures

A new program is checked by executing it in some or all of the verification modes. Dry run with Machine lock Used for checking syntax errors. Motion errors are not checked. Set Machine lock ON and Dry run ON. Set feed rate override switch to maximum to execute the cycle fast. The spindle rotates, the turret indexes and the display changes as per program, but axes do not move. Tool and work offsets need not be set.

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Dry run with air cutting Used for checking motion errors and correctness of spindle direction. Since execution is at dry run feed, difference between rapid and feed motions is not known. Collisions cannot be checked. Set the tool offsets. Set the work offset so that all motions occur away from work holding devices like the chuck.. Do not load a part. Set Machine lock OFF and Dry run ON. All machine functions and motions are active. Set feed rate override switch to minimum for safety. Normal cycle with air cutting Used for checking collisions. Set the tool offsets. Set the work offset so that all motions occur away from work holding devices like the chuck.. Do not load a part. Set all functions for normal machine execution. For safety, when in doubt set the feed rate override switch to minimum. Carefully watch for motions which result in tool colliding with the part or work holding device. Single block execution Used for checking motion errors and part dimensional accuracy. Set the work offset normally, and load a part. Set the tool offsets to leave excess stock on the part. Set all functions for normal machine execution. For safety, when in doubt set the feed rate override switch to minimum. Check the Distance to go value to detect potential motion errors. Check all dimensions. For critical dimensions alter the tool offsets and rerun the tool again to check whether the dimension is within tolerance. Repeat till tolerance is achieved.

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