COMPUTER-AIDED PART PROGRAMMING

The manual part programming is a time consuming process and needs an expert part programmer who
should have through knowledge of the various machining processes, materials, speeds and feeds, part
programming codes and capabilities of various machine tools, etc. Manual part programming is a
labour oriented task and needs skilled programmers. Also, if a person is expert in programming one
machine, he will not be able to develop part programme for another machine, since the format or the
type of information required by the two machines may be different. With the modern NC/CNC
machines where more than three axes are to be controlled it may not be possible to develop part
programmes by manual programming methods.

All these problems have been overcome and part programming has been considerably simplified with
the use of computer aided part programming, where the computer generates the part programme
required to machine the component. The process of generating part programmes in computer aided
part programming is partly done by part programmer and partly by the computer.

The part programmer's job in the computer aided part programming is first to define the geometry of
the component from the component drawing. The geometry or shape of the component is split into
simple elements like points, lines, arcs, full circles, distances and directions and these elements are
assigned specific numbers to identify their position. The geometry of elements of the component is
defined using simple abbreviated English like terms having specific meaning which is understood by
the computer and control system. The instructions to define a point and straight line may be written
as:

Pl/0, 0 (co-ordinates of point PI are (0, 0))

L1/P2, P4 (line L1 passes through points P2 and P4)
The programmer may be able to see the geometric construction on the video display unit depending
upon the system capabilities. The second part of the programmer's job is to give additional information
regarding the machining sequences, type of operation, tool sizes, etc. From the geometry of the
component, the system generates the data required to machine the component. This data is called cutter
location (CL) data. The data generated up to this point is independent of the machine and can be used
on any machine capable of doing the required operations. The data does not contain G or M codes.
The cutter location data is then post-processed in the computer to translate it into a form which a
particular machine control system can understand. The post-processing involves addition of G Codes,
M codes and other machine dependent information in the required format.
The part programme at this stage is machine dependent and can be used for a specific machine only.
The advantages of using computer-aided part programming are:
(a) Part programming is considerably simplified.
(b) The part programmes generated are accurate and efficient.
(c) All arithmetic calculations are done by the computer, resulting in saving in time and
elimination of errors.
(d) The part programming for different machines can be done by a single person, which can then
be post processed for specific machines.
(e) Such system can deal with many axes for simultaneous movement.
(f) If new machines are added, only a post processor may be needed to integrate the new machines
with the existing system.

SUBROUTINES, DO-LOOPS, CANNED CYCLE.

Subroutines
· Subroutine also called subprogram are a powerful time saving technique.
· The subroutine provide the capability of programming certain fixed sequence or frequently
repeated patterns.
· Subroutines are in fact independent programmes with all the features of a usual part
programme.
· Subroutines are stored in the memory under separates programme number.
· Whenever a particular feature is required within the programme the associated subroutine is
called for execution.
· The subroutine may be called any time and repeated any numbers of time.
· After execution of subroutines the control return to main programme. To describe and use a
subroutine, the following information is required in the form of codes and symbols.
Ø Identification (start) of subroutine.
Ø End of subroutine.
Ø A mean of calling a subroutine.
· Here we will use letter L followed by a number i.e L221, to identify the start of a subroutine.
· L221 means start of subroutines No. 221, Miscellaneous code M17 will indicate the end of
subroutine.
· The subroutine can be called anywhere in the main programme by just giving the subroutine
number preceded by letter L.

Do-loops
· The ability to write the programme with loops enable the programmer to instruct the control
unit to jump back to an earlier part of the programme and execute the intervening programme
blocks a specified numbers of time.
· The DO-LOOPS statement is given in the main programme itself and it is necessary to give
following information on the form of symbols or codes.
Ø Start the Loop.
Ø Number of repeats of the Loop.
Ø End of the Loop.
· DO-LOOPS is used for repetitive programming in cases such as Turning & Milling operation
where it is not possible to remove the entire material in the single pass and more than one cut
have to be taken to machine the component to require size or where uniform repetition is
required like cutting uniformly spaced grooves in a shaft or drilling of a pattern of hole in plate.
 Canned cycle
· Canned Cycle or fixed cycle may be defined as a set of instruction, inbuilt or stored in the
system memory, to perform a fixed sequence of operation.
· The Canned Cycles may be brought into action with a single command and as such reduce the
programming time and effort.
· Canned Cycles are used for repetitive and commonly used machining operation.
· The Canned Cycles are stored under G-code address. G 81 to G 89 are reserved for fixed Canned
Cycles and G 80 is used to cancel the Canned Cycles.

APT
APT stands for automatically programmed tools. This is the most widely used and most
comprehensive part programming language available. APT is a three-dimensional system which can
be used to control up to five axes. In programming using APT, it is assumed that the workpiece remains
stationary and cutting tool does all the moving. The APT part programme consists of four types of
statements.
(i) Geometry statements: These are also called definition statements and are used to define
geometric elements like point, circle, arc, plane, etc.
(ii) Motion statements: The motion statements are used to define the cutter path.
(iii) Post processor statements: These statements are applicable to specific machine tools and are
used to define machining parameters like feed, speed, coolant on/ off, etc.
(iv) Auxiliary statements: These are miscellaneous statements used to identify the part, tools,
tolerances, etc.

PART PROGRAM
1) Part Programming for drilling. ( 5mm hole depth)
 N010 G71 G90 G94 T01;
N020 M03 S800 F200 M08;
N030 G00 X0.0 Y0.0 Z5.0;
N040 G00 X10.0 Y10.0;
N050 G01 Z-5.0;
N060 G00 Z5.0;
N070 G00 X50.0;
N080 G01 Z-5.0;
N090 G00 Z5.0;
N100 G00 Y30.0;
N110 G01 Z-5.0;
N120 G00 Z5.0;
N130 G99 M02;
N140 M05 M09;

2) Part Programming for Turning. ( Turn the ø26mm )

N010 G71 G90 G94 T01;

N020 M03 S800 F200 M08;
N030 G00 X0.0 Z5.0;
N040 G00 X28.0;
N050 G01 Z-60.0;
N060 G00 Z0.0;
N070 G01 X26.0;
N080 G01 Z-60.0;
N090 G00 Z0.0;
N100 G99 M02;
N110 M05 M09;
3) Part Programming for Turning Raw material ( Þ 20mm facing & step turning )

N010 G71 G90 G94 T01;

N020 M03 S800 F200 M08;
N030 G00 X0.0 Z5.0;
N040 G00 Z0.0;
N050 G01 X28.0;
N060 G01 Z-50.0;
N070 G00 Z0.0;
N080 G01 X16.0;
N090 G01 Z-50.0;
N100 G00 Z0.0;
N110 G01 X14.0;
N120 G01 Z-35.0;
N130 G00 Z0.0;
N140 G01 X12.0;
N150 G01 Z-35.0;
N160 G00 Z0.0;
N170 G99 M02;
N180 M05 M09;
4) Part Programming for Turning, Raw material ø32mm. ( Step turning )

N010 G71 G90 G94 T01;

N020 M03 S800 F200 M08;
N030 G00 X0.0 Z5.0;
N040 G01 X30.0;
N050 G01 Z-67.0;
N060 G00 Z0.0;
N070 G01 X28.0;
N080 G01 Z-37.0;
N090 G00 Z0.0;
N100 G01 X26.0;
N110 G01 Z-37.0;
N120 G00 Z0.0;
N130 G01 X23.0;
N140 G01 Z-37.0;
N150 G00 Z-15.0;
N160 G01 X20.0;
N170 G01 Z-37.0;
N180 G00 Z-22.0;
N190 G01 X18.0;
N200 G01 Z-33.0;
N210 G00 Z-22.0;
N220 G01 X15.0;
N230 G01 Z-33.0;
N240 G99 M02;
N250 M05 M09;
5) Part Programming for Taper Turning, Raw material ø40mm.

N010 G71 G90 G94 T01;

N020 M03 S800 F200 M08;
N030 G00 X0.0 Z5.0;
N040 G01 X40.0 Z0.0;
N050 G01 Z-20.0;
N060 G01 X20.0 Z-35.0;
N070 G01 Z-55.0;
N080 G01 X40.0 Z-70.0;
N090 G01 Z-100.0;
N100 G99 M02;
N110 M05 M09;

6) Part Programming for Turning in system, Raw material ( ø20mm facing, ø15mm taper
turning )
 N010 G71 G90 G94 T01;
N020 M03 S800 F200 M08;
N030 G00 X0.0 Z5.0;
N040 G00 X20.0;
N050 G01 Z-35.0;
N060 G00 Z0.0;
N070 G01 X17.0;
N080 G01 Z-15.0;
N090 G00 Z0.0;
N100 G01 X15.0;
N110 G01 Z-15.0;
N120 G01 X20.0 Z-20.0;
N130 G99 M02;
N140 M05 M09;
7) Circular Interpolation

N010 G71 G90 G94 T01;

N020 M03 S800 F200 M08;
N030 G00 X0.0 Z5.0;
N040 G00 Z0.0;
N050 G02 X10.0 Z-5.0 R5.0;
N060 G01 Z-15.0;
N070 G03 X20.0 Z-5.0 R5.0;
N080 G01 Z-40.0;
N090 G99 M02;
N100 M05 M09;
8) Circular Interpolation

N010 G71 G90 G94 T01;

N020 M03 S800 F200 M08;
N030 G00 X0.0 Z5.0;
N040 G00 Z0.0;
N050 G02 X10.0 Z-5.0 R5.0;
N060 G01 Z-10.0;
N070 G03 X20.0 Z-15.0 R5.0;
N080 G01 Z-25.0;
N090 G01 X10.0 Z-35.0;
N100 G01 Z-50.0;
N110 G03 X20.0 Z-55.0 R5.0;
N120 G01 Z-70.0;
N130 G99 M02;
N140 M05 M09;
9) Write part programme for milling, thickness of plate 10mm, T01 facing, T02-ø7mm, T03 –
ø13mm.

N010 G71 G90 G94 T01;

N020 M03 S800 F200 M08;
N030 G00 X0.0 Y0.0 Z5.0;
N040 G01 X90.0;
N050 G03 X110.0 Y20. R20.0;
N060 G01 Y59.0;
N070 G00 X0.0 Y0.0;
N080 G00 M06 T02;
N090 G00 X37.0 Y20.0;
N100 G01 Z-10.0;
N110 G01 Z5.0;
N120 G00 X90.0;
N130 G00 M06 T03;
N140 G01 Z-10.0;
N150 G00 Z5.0;
N160 G99 M02;
N170 M05 M09;