CNC Setups

E CNC Setups

Parts must be located precisely and held securely during the machining
process. Work holding devices are referred to as fixtures. A fixture can
be as simple as a vise with hard jaws. Very complex fixtures, like those
used in the aerospace industry, may cost many thousands of dollars and be
designed by highly experienced tooling engineers.

Devising efficient and effective fixtures is one of the most challenging

tasks of programming a CNC Mill, requiring a high level of knowledge,
skill, and ingenuity. A few of the many factors influencing work holding
include:
 Type of material being machined.
 Number of sides of part to machine.
 Feature tolerances.
 Machining forces.
 Rigidity of the part; before an after material is machined away.
 Cost to manufacture the fixture.
 Number of times the fixture will be used.
 Skill level of the machine operator.

For example, many parts can be accurately located and held in a vise. If
the part is machined on several sides, pay careful attention to the order
each face is machined and how the part is flipped between operations.

Production quantity is an important consideration. Higher production

volumes usually justify more expensive tooling to speed production and
reduce scrap rate.

Size and type of material and cutting forces also affect fixture choice. A
foam or plastic visual prototype may be simply glued or taped down.
More substantial parts can be bolted, clamped, or held with a vacuum.

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 Appendix E

CNC A basic vise setup uses a vise, step jaws, vise stop, and stock material
Setups machined to size. The back edge of the fixed step jaw is dial indicated
Vise
parallel to the machine x-axis. The vise stop sets a limit to slide the stock
against as fresh stock material is loaded.
Vise Fixed
Stop Jaw

Movable
Back Edge of Jaw
Fixed Jaw
Parallel To
Machine X-Axis

Stock cut Back Edge

To size. Step Jaw
Stock

Step
Jaws

Improperly designed setups are extremely dangerous. Parts, tooling, or

fixture components can shatter or be ejected at high speed, causing
serious injury or death. Always wear safety glasses and observe all
Warning machine safety procedures. Unless you are completely confident your
setup will securely hold the part, do not use it.

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 CNC Setups

The following diagram shows the layout of a typical VMC and location of
the spindle when the machine is at its Home Position.

Y
Y

X
X

Top Iso

Z Z

X Y

Front Side

CNC programs are written in terms of the tool tip motion; not table
motion. For example, a command of X1.0 moves the tool to the right
(though on a VMC the table will move to the left).

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 Appendix E

Fixture Your probably noticed that when the machine is at its home position, its
Offsets
coordinate system datum is far away from the part datum. Here is why.

When you first power-up a CNC machine, it has no idea where the spindle
is located in the workspace. The machine finds its position during the
startup-home process by simply driving each machine axis towards its
(-) limit. Just before the machine hits an axis limit, it trips a micro-switch.
This signals the control that the axis is at a known location; called the
Machine Home. Home is usually defined as the center-face of the
spindle when the machine is at its (-) axes limits.

Once homed, the machine keeps track of its position by counting how far
each axis moves in reference to Home. Coordinates in reference to
Machine Home are called Machine Coordinates.

Of course, no one programs using Machine Coordinates. The Machine

Home position is far from the work piece, so programs written in Machine
Coordinates would have numbers that bear no obvious relation to
coordinates on the part.

If the fixture were removed, it would be difficult to put it back exactly

where it was, so the NC program would have to be re-written to account
for any difference. Besides, the part has its own datum, and NC programs
written in reference to the Part Datum are lot easier to understand.

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 CNC Setups

Any point on the part or fixture can be used to find the part datum, as long
as you can reliably measure its position.

In this example, Exercise 3-9, Fixture Plate, the material is machined to

finished size before loading it into a standard six-inch vise with step jaws.
The top of the finished material is Z-Datum.

The fixed (back) vise jaw is dial indicated parallel to the machine X-axis.
A Vise Stop, in this case an adjustable rod, allows stock material to be
loaded into the vise in the exact same position each time.

The part datum must be located precisely; typically +/- .001 or less. There
are many ways to find the part datum. In this example, the XY-Datum is
easily found using and Edge Finder to locate the back and left edges of the
part.

Vise
Fixed
Stop
Jaw

Movable
Back Edge of Jaw
Fixed Jaw
Parallel To

X
Back
Edge
Stock c ut

Z
Step
Jaws

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 Appendix E

Fixture The coordinate system is shifted from Machine Home to the Part Datum
Offset using a Fixture Offset. A fixture offset is simply a record machine
Registers
(G54-G59) control keeps of the distance between the Machine Home position and the
Part Datum point. Each time the NC program commands a move, the
control checks this record, or Register, and internally adds this value to
that move.

Fixture offsets are usually assigned G-codes G54 thru G59, though some
machines allocate more. Each fixture offset has a XYZ shift value. When
a fixture offset G-code appears in the NC program, the control looks at the
register values for that offset, and adds these values to any subsequent
moves.

In this example, the G54 offset register is called on line (N2) of the NC
program. This line of code moves the center of the spindle from the
Machine Home position to directly above the Part Datum.
Fixture Offset Table On Control
Mac hine G54 X12.6830 Y -7.1590 Z00.0000
Home G55 X 00.0000 Y00.0000 Z00.0000
Shift_X G56 X 00.0000 Y00.0000 Z00.0000
N1 G57 X 00.0000 Y00.0000 Z00.0000
G58 X 00.0000 Y00.0000 Z00.0000
Shift_Y
N2
-7.159
12.683

N1
N2 G54

Part Tool
Datum Motion

Sample NC Program
N1 T1 M6
N2 G90 G54 G0 X0. Y0.
N3 S7200 M3
N4 G43 H1 Z1. M8

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You probably noticed that the fixture offset in this example was used only Tool
to shift the datum in X-Y, not Z. This is because the Z shift distance Length
Offsets
changes depending on the tool length — how far the tool extends below (H)
the center-face of the spindle. Most tools are different lengths. Length
may even change when you replace a worn or broken tool.

Shifting the Z-datum is accomplished using Tool Length Offsets. Tool

offsets work similar to fixture offsets; letting the machine know the
location of the tip of the tool in relation to the part Z-datum. Each tool has
its own Tool Length Offset number. For most machines, this is an H-
value that is the same number as the tool (T1 uses H1, T2 uses H2, etc).

The H-value is called in the G-code file with the first rapid move to depth
along with a G43 (Read Tool Height Offset Register). This causes the
machine to look at the H-register value and add this to the move.
Tool Offset Ta ble On Control
Tool# Height (H) Dia (D)
1 -11.913 00.0000
Mac hine 2 00.000 00.0000
Home N2 3 00.0000 00.000

N4
Part Shift_Z
Datum N5

Tool
Length

Home Z-Datum
To
Part Z-Datum Shift_Z
(-11.913)
Sample NC Program
N1 T1 M6 N4
N2 G90 G54 G0 X0. Y0.
N5
N3 S7200 M3
N4 G43 H1 Z1. M8
N5 Z0. F3.

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The previous illustration shows the simplest way to use tool length offsets.
This method is widely used in prototype and short production work.
 The tool is jogged to the Part Z-Datum (in this case, the top of the
part).
 The incremental distance moved in Z from the home position to
the top of the part is recorded and entered in the appropriate Tool
Length Register.
 This value represents the shift in Z from the machine home to the
Z-Datum of the part.
 The value is usually negative; the machine subtracts this value
from the Z-position of the spindle, shifting the tool down towards
the part.

Another method uses what is called preset tooling. This is used more
often in larger companies and long production run work:
 The tool length (distance from the center-face of the spindle to the
tip of the tool) is accurately measured in the tool room.
 This gage length is entered in the tool-offset register as a positive
value.
 The fixture offset Z-value represents the distance from the center-
face of the spindle to the part Z-datum.
 Internally, the control first subtracts the fixture offset from a
command move. It then adds the tool gage length to the move.

Some machines have automatic tool probes which measure the length
automatically. Follow the instructions in the machine operator manual
for use of tool and fixture offsets with a probe.

There are other ways to use fixture and tool offsets. They all work, and
companies have good reasons to adopt a particular method. But, once
you understand how fixture and tool offsets work, will easily adapt to
whatever method your company or school uses.

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Plate work refers to machining sheets or plates of material. The material CNC
is manufactured to a specified thickness that is the same as the finish Setups
thickness of the part, so no facing operation is required.

The purpose of the fixture plate is to accurately locate the stock material
and then keep the part from moving during machining.

The illustration below shows a typical fixture plate. The fixture base is
machined flat, square, and parallel. Notice the plate is engraved with the
part name and coordinates of the part datum in reference to the upper-left
corner. This makes it easier to reuse the fixture plate.

A) Fixture Base
B) Clamp (2X)
E C) Dowel Pin (3X)
D) Washer (2X)
E) Bolt (4X)
D

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Example The fixture plate below shows the setup just before the first machining
Fixture operation. After the holes are drilled and bolts inserted through the part,
Plate
the dowel pins and clamps should be removed if there is any possibility of
a collision with the tool or holder.

Stock Material
Aluminum Sheet
5.0 x 2.5 x .063

Aluminum Base
6.0 x 5.0 x .625

Clamp
.5 x 1 x .25 Dowel Pin
.250 x .625
Bolt
1/4-20 x .75 Reamed Hole
.251 x .375 Deep

1/4-20 Tapped Thru Vent Hole

.093 Thru

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Component Description Fixture

Fixture This is the base on which the fixture is built. For short Plate
Components
Plate production and prototype parts, an aluminum plate is
commonly used. It is machined flat, square and parallel.

De-burr all sharp edges and holes so the stock lies flat on
the surface and is not scratched.
Stock Sheet aluminum stock that is within specification in
thickness.

Since a OD contour cut is made all around the part, stock

can be sheared or saw cut to approximate size.

De-burr and inspect material before placing it in the

fixture.
Dowel Pins Dowel holes are drilled and reamed to a diameter of .251 x
.375 deep providing a slip fit in the holes.

A .093 vent hole is drilled from the bottom of the reamed

hole through the bottom of the plate. This allows air to
enter into the space between the bottom of the dowel pins.
Without it, the dowel may become impossible to remove
due to the vacuum created with a blind hole.
Washers Steel cap screws will mar aluminum. Place an aluminum
washer or pad between clamps and an aluminum surface.
Cap Two screws hold the clamps in place during drilling
Screws operations. Others are installed to hold the plate down
during the OD contour cut.
Clamps Simple shop-made aluminum clamps hold the part during
drilling.

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Component Specification
Components
Specifications Fixture 6061-T6 Aluminum
Plate Width: 6.00
Height: 4.25
Thickness: .625 (5/8)
Stock 6061-T6 Sheet Aluminum
Width: 6.00
Height: 4.25
Thickness: .063
Dowel Pins Ground Steel
Diameter: .250
Height: .625 (5/8)
Install: .375 Deep
McMaster-Carr p/n:

Washers Aluminum
ID:.266
OD:.50
Thickness: .064

Cap ¼-20 Socket Head

Screws
OD: .250 Thread
Head Dia: .375
Grip Length: .75
McMaster-Carr p/n:

Clamps 6061-T6 Aluminum

Width: .5
Height: 1.0
Thickness: .25
Step: .063
D-Hole: .26 WD x .50 HT
Shop Made

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The following steps show how a simple fixture plate may be setup and Process
Overview
used on a vertical machining center.

Setup
1) Fixture can be clamped to
machine table or clamped in a
vise.
2) Vise fixed jaw is aligned with
machine X-axis.
3) Left-Back edge of fixture can
be located as a reference point.

Step 1: Load Material

1) Inspect stock material
2) Slide Stock Against Dowels
3) Tighten Clamps
4) Remove Dowel Pins if any
Possibility of collision.

Step 2: Drill Holes

1) Spot Drill (2X)
2) Drill .250 Holes Thru Part (2X)

Remove dowel pins after clamps are tightened if there is any

chance of the tool impacting the pins.
Warning

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Step 3: Install Bolts

1) Ensure holes are clear
2) Install 1/4-20 Cap Screws
and Aluminum Washers

Step 4: Contour OD
1) Machine OD with 3/16 End
Mill.
2) Provide sufficient lead-in to
Clear stock.

Step 5: Prepare For Next Part

1) Remove remnant
2) Clear area and holes
3) Install Dowel Pins
4) Inspect part
5) Handle part carefully to
Prevent marring or damage.

The machine operator is responsible for part quality. This is more

than just adjusting a machine offset to ensure the part is within
specification.

Exercise care when handling parts, and keep a clean work area.
Remember
Strive to deliver quality in everything you do. Parts that are
properly de-burred and are not marred in any way by mishandling
are the mark of a professional machinist.

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In cases where you need to position a plate with existing holes, never rely Shoulder
Bolts
on threaded holes to locate the part. Instead us Shoulder Bolts (aka
Stripper Bolts).

Counterbore a hole in the fixture plate the diameter of the bolt shank.
Drill and tap a hole in the bottom of this counterbore to screw in the
shoulder bolt.

Shoulder Bolt

Ground Shank
Located in Counterbore Hole

Shoulder Bolt Usage

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Notes:

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