Drawing & Dimensioning Grading

Guideline for grading Paperweight drawings, and drawings produced in the Yo-yo labs.

Dimensioning features where points will be taken. First occurrence basis per report based on a
perfect score of 10.

0.1 Point issues:

1. Line thickness: dimensions, center lines, phantom lines, leaders, and arrows, to be finer than
drawing lines
2. Missing center lines
3. Missing center points
4. Missing arrows, unless ordinate dimensioning is used
5. Both arrows point same way

0.2 Point issues:

6. Showing tangencies.
7. Arrows pointing to radii at quadrants, or arrows do not point to or go through the center of the
radius.
8. Overlapping dimensions, arrows, or leaders. General clutter causing difficulty reading print.
9. Not using an extra print when necessary to minimize clutter, or to clarify a detail.
10. Double dimensioning
11. Wrong way to show dimension, such as showing a diameter as a radius, or visa versa
12. Having dimensions in parenthesis when you do not intend the dimension to be shown as a
reference dimension
13. Missing lines
14. Dimensions within a view
15. If using multiple sheets, not specifying there are other sheets, i.e. sheet 1 of 2, sheet 2 of 2, and so
on
16. Mixed, or wrong Angle Projections. In America we sweep (3rd angle projections), in Europe they
roll (1st angle projections).
17. Cross-sections not oriented, or displayed properly.
18. Different size fonts.
19. Dimensioning to tangencies.
20. Extra dimensions that are not necessary.
21. Wrong values.
22. Wrong line type.

0.5 Point issues:

23. Missing dimensions

24. Not showing whole part, except for the Lab I deliverable where the top view can be a separate
drawing from the profile view. The Lab III requirement is to combine the views.
25. Not specifying engraving depth and tool to use as a note.
26. Design shows major geometry features that cannot be machined with tooling provided, such as
groove depths designed deeper than the length of cut for the tool.
27. Missing features for snap fit; draft where there should be straight wall engagement.
28. Dimensions upside-down.

1.0 Point issues

29. Conflicting dimensions between mating core and cavity molds: i.e. height of core exceeds depth of
cavity.

2.008 Design & Manufacturing II Drawing & Program Grading

 Part Program Grading
Guideline for grading Paperweight, and Yo-yo lab programs.

Programming features where points will be taken. First occurrence basis per program based on a
perfect score of 10.

0.1 Point issues:

1. Missing decimal points.(mill)

2. Lowercase letters.(mill)
3. Letter ‘O’, instead of number ‘0’ in ‘G’ words (mill)
4. ‘Z’ feed cutting level in positive area (above part) (mill)

0.2 Point issues:

5. Facing with inappropriate tool. (mill, or lathe)

6. Missing a G0 Z.1 at tool start-up. (mill)
7. Missing an X, and Y movement at tool start-up. (mill)
8. Rapid Z move on same block as X, and Y move. (mill)
9. G1, and G2 on same block. (mill)
10. Two ‘M” codes on same block (mill)
11. 2 feeds on same block. (mill)
12. Tool pick-up and X, Y move on same block. (mill)
13. Turning backwards, (from chuck towards turret). (lathe)
14. Using a trepanning tool where a larger tool would be more suitable for the operation. (lathe)
15. Finish cuts at roughing feed rates. (lathe)
16. Rapid move to Z.1 before positioning to in the X, and Y axes first, at tool start-up. (mill)
17. Using wrong tool for trepanning. (lathe)
18. Not including a feed when last tool used had a feed that is inappropriate for the new tool picked
up. (mill)
19. Missing a G90 on Z moves after being in G91 mode for the X, and Y moves.(mill)
20. Missing ‘M26’, and ‘M30’ to end program (mill)
21. Missing ‘R’ on G2, and G3 moves. (mill)
22. Missing quadrant points on arc moves. (mill)

0.5 Point issues:

23. Plunging too deep for selected tool. (mill, and lathe)
24. Missing a Z retract before positioning to a new location. (mill)
25. Missing a ‘G1’ on the Z move that goes back into the part after rapid positioning to a new
location. (mill)
26. Not returning to a G1 after being in a G2, or G3 move when the intent was to go back to linear
motion, from circular motion.(mill)
27. Turning OD to Z-.5. (lathe)
28. Missing workshift designation after each tool pickup (G55, G56, G57). (mill)

2.008 Design & Manufacturing II Drawing & Program Grading

 2.008
Design & Manufacturing II

The Discrete Parts Manufacturing

Lab IV:
Product Design
Lab V:
Tooling Design
Lab VI:
Tooling Fabrication
Lab VII:
Parts Production
Lab VIII:
Product Inspection: Quality & Variation

OBJECTIVE 2

INTRODUCTION 2

ORGANIZATION 2

LAB IV: PRODUCT DESIGN 2

LAB V: TOOLING DESIGN 3

LAB VI: TOOLING FABRICATION 3

LAB VII: PARTS PRODUCTION 3

LAB VIII: PRODUCT INSPECTION: QUALITY & VARIATION 3

DELIVERABLES 3
 Labs IV-VIII
OBJECTIVE
This exercise requires student teams to design and manufacture a three-part, or four-part yo-yo.
The goal is to follow a typical product design/manufacturing sequence. The steps include:

1) Designing a product to be manufactured,

2) Designing the tooling to be used to form the parts for the product,
3) Machining the tooling with computer numerically controlled (CNC) machine tools,
4) Optimizing (tuning) the manufacturing processes,
5) Manufacturing a batch of product, and
6) Characterizing the manufactured products.

These exercises provide an opportunity to apply what you have learned about CAD/CAM, to learn about commonly used
manufacturing processes, and to recognize some issues concerning the optimization of a manufacturing process. One of the
lessons that can be learned by going through this progression is that the process and the tooling impose limitations on the part
design. As an example, whether the part is thermoformed or injection molded, it must be easily removable from the forming
tool. Thus, we will see that for best results the product and the process (in this case the tooling) must be considered
simultaneously.

INTRODUCTION
Forming processes are used to produce a tremendous variety and quantity of parts. Examples of forming processes for metal
include casting and sheet metal forming. Two forming processes for polymeric materials, injection molding and
thermoforming, will be the focus of this laboratory sequence. The lessons learned from examining injection molding and
thermoforming will be applicable not only to plastic materials, but to metals and ceramics as well.

All forming processes have one essential ingredient in common. They all rely on a tool, die, or mold to create the geometry
of the finished part. In general, each new part design demands the creation of a new tool or die. This situation contrasts
greatly with machining, where a set of cutting tools can be used to create a wide variety of finished shapes. Thus, we see that
forming processes are less flexible to design changes than machining processes. However, forming processes result in net
shape or near net shape parts. Thus, the use of forming processes is a balance between the cost and time associated with
creating the tool or die and lower cost per part when making a large number of parts.

ORGANIZATION
Since the project will take several weeks to complete, we have broken the exercise into small segments: Labs IV, V, VI, VII,
and VIII. During these labs students are organized into groups. Each group will design its product together and should
delegate responsibility to specific individuals/teams for the manufacture of each of the component parts you intend to
produce.

Lab IV: PRODUCT DESIGN

Each yo-yo group will design a yo-yo that has two, or three injection molded parts, and one, or two thermoformed parts. The
designs, which you submit, are required to specify the increment of interference that you intend, and the dimensional
tolerance that you anticipate will provide adequate service.
An example of an exploded assembly drawing of a yo-yo can be found in the ‘Lab Handouts’ folder in the course locker.
Mold blank dimensions can be found in the ‘Mill Injection Molding Blanks’, and ‘Lathe Injection Molding Blanks’ folders.
Prints of the ‘Punch and Die Set’ blanks, as well as a ‘Thermoform Mold Blank’ are in their respective folders.

2.008 - Design & Manufacturing II -2- The Discrete Parts Manufacturing

Design requirements:

• Yo-Yos should be made of 2-3 injection-molded parts that snap fit together, and at least 1 thermoformed part

• A set of ejector pins can be used if the injection-molded parts are not easily removable from the two-piece molds

• Each injection-molded part cannot exceed 2.7 cubic inches in volume

• The maximum outside diameter of the injection-molded parts cannot exceed 2.5” in diameter

• High impact polystyrene ‘HIPS’ sheet of .020”, .030”, and .040” thickness is provided for thermoformed parts

• Polypropylene is provided for the injection-molded parts, various colors are available

• Appropriate spec ranges (tolerances) must be specified for the dimensional features of each part

Lab V: TOOLING DESIGN

Team members will design the molds needed to produce the required parts and use Mastercam to generate “G” code to direct
the motion of the machine tools to produce these molds. Team members must confer with teammates to reach agreement on
common dimensions and intended interferences to ensure snap-fits. All molds will be machined from aluminum. Ejector
pins can be used if the design warrants the need for them. Team members responsible for the thermoformed part will
machine their designed shape into a mold blank measuring 3.0” in diameter X .625” thick. They will also have an option to
design, and machine a punch-and-die set for trimming the finished part from the material. The punch-and-die set will be
made from low carbon steel. Prints for all the blanks, including the punch-and-die blanks are posted in the course locker, as
well as a print showing the location and size of the ejector pin holes for the injection-molding blanks.

Be sure, when importing your design to the mold blank templates, that you locate the center of the product in the center of the
blanks.

Lab VI: TOOLING FABRICATION

Students will machine their molds using the CNC machine tools in the laboratory.

Lab VII: PARTS PRODUCTION

Students will use the injection molding and the thermoforming machine to produce enough parts for fifty assembled products.
Students are expected to optimize the process for the desired quality features and to become proficient in the operation of the
injection molding and thermoforming machines before beginning the production run. Student teams will divide
responsibilities to permit molding, trimming and sequence numbering for the creation of a run chart. During the production,
at about fifty pieces, a process parameter (e.g. cooling time, or sheet thickness) is to be altered to simulate a process
disturbance to induce a mean shift of a part feature dimension.

Lab VIII: PRODUCT INSPECTION

Injection molded parts should be allowed to cool for a minimum of 30 minutes before measuring. Select one dimension on
each injection molded part and one dimension on each thermoformed part to study the dimensional variation in
manufacturing. Preferably the critical feature dimensions involved with the snap-fit aspect of the design.

DELIVERABLES
You are required to submit 4 reports as indicated below during the Discrete Parts Manufacturing progression. A statement
should accompany each report attributing authorship, by section, to an individual student, and a joint evaluation of the
relative contribution of each group/team member to the entire Discrete Parts Manufacturing exercise. Each group/team
member must sign this statement. Your statement should appear as:

Student A 20% Student C 25% Student E 30%

Student B 15% Student D 10%

2.008 - Design & Manufacturing II -3- The Discrete Parts Manufacturing

Definitions: A ‘Group’ is the entire Yo-yo group. A ‘Team’ is a pair of students within the group responsible for their
assigned parts. Grading: The entire ‘Group’ will receive a common grade on group reports. Each ‘Team’ will receive a
grade on their particular team report.

Do not forget to include the agenda and minutes for each meeting.

Each report should contain the following:

Report 1: (10 points) Group report, due one week after the lab, at the beginning of the
next lab session.
1. An outline of the planned division of labor for the complete lab progression (i.e. who’s doing what
for Labs V, VI, VII, VIII)
2. Fully dimensioned drawings of each of the parts using Mastercam, or Solidworks.
3. An assembly drawing.
4. An explanation of how you incorporated the design requirements into the features of your product
design.

Report 2: (10 points) Team report, due one week after the lab, at the beginning of the
next lab session.
1. A fully dimensioned Mastercam, or Solidworks drawing of the molds.

2. The complete set of G-code programs for machining the mold component. Send the completed
programs to the appropriate folders on crossshop1, or crossshop2, identify by including your Athena
username in the file name. Please do not print the code.

3. A justification for the dimensions you have established for your mold contours (i.e. how did you
calculate your shrinkage allowances?)

4. Select any 10 blocks of the G-code from one of your programs, the blocks must be in sequence. Print
just the 10 blocks and submit an explanation of what the blocks of code are doing. For the lathe
select movement blocks since the meaning of some of the lathe code isn’t covered in lab.

Report 3: (15 points) Team report, due April 9th by 5PM for all lab groups.

1. Justification and discussion of the process optimization and possible mold redesign.

Report 4: (10 points) Group Report, due April 30th by 5PM for all lab groups.
1. A run chart showing the relevant dimensional features of each component part. (i.e. a run chart for
the dimension measured during production. A separate chart for each part.)
2. A histogram of the critical dimensions which you monitored during your production run.
3. Plot a Shewhart X-bar chart. Explain how you chose the size of your “rational subgroup.” Where did
you place the control limits and why? Can you detect the step change induced by the parameter
change you made midway through your production run? Why or why not?
4. What is the process capability, Cp, for your process, given the spec range you indicated in the
exercise undertaken in Lab IV?

5. What were the restrictions (number of components, material, process limitation, etc.) on the part
design? Suggest an alternative design when there are no restrictions (mechanical drawings are not
required).

2.008 - Design & Manufacturing II -4- The Discrete Parts Manufacturing

 2.008
Design & Manufacturing II

The CAD/CAM Labs

Lab I
Process Planning
G-Code
Mastercam Lathe

Lab II
Mastercam Mill
Check G-Code
Lab III
CNC Mill & Lathe Machining

OBJECTIVE 2

BACKGROUND 2

LAB EXERCISES 3

DELIVERABLES 4

APPENDIX A: PRODUCING THE SAMPLE PART 5

APPENDIX B: PROGRAMMING MACHINE TOOLS 7

 Labs I, II, III

OBJECTIVE
These lab exercises will introduce you to process planning and the tools you will need to carry through on such a
plan. In the end (lab III) you will produce a machined paperweight with your own unique inscription. You will
become familiar with a CNC lathe and a CNC mill, as well as Mastercam, a computer-aided manufacturing software
package. You will also learn G-code, the alphanumeric programming language used to control CNC machine tools.

BACKGROUND
Process planning is an engineering activity that determines the appropriate procedures for transforming raw
materials into a final product as specified by an engineering design. Engineering designs are conventionally
documented using detailed diagrams indicating important design characteristics such as dimensions, tolerances,
materials, and other pertinent specifications. Even though these diagrams convey a large amount of information
about a design, they are incomplete in that they do not describe the manufacturing steps necessary to produce the
final part. Effective process plans provide this information. In practice, design, process planning, and
manufacturing are interrelated since the capabilities and characteristics of available equipment, manufacturing
processes, and personnel can have a significant impact on the final design of a product.

G-code

When the designed product is produced using CNC machine tools, the machine tool controller needs explicit
instructions describing the type and order of individual steps required to perform a given task. These instructions
are provided to the controller in the form of alphanumeric codes (G-code) and are usually called a part program. A
complete listing of G-code commands and a set of example code/part pairs can be found in the appendices.

G-code itself can be written with any number of text editors, including the Windows notepad and, of course, emacs.
After the code is verified with a simulation, it is loaded into one of the CNC machines.

Mastercam

Mastercam is a commercial Computer Aided Manufacturing software package. CAM is the process that links CAD
(computer-aided design) with machine tools by automatically producing CNC code from a drawing. Mastercam
includes a CAD environment, a geometry-to-G-code translator, and a G-code simulator. It is possible to import
geometry from other drawing tools like AutoCAD, SolidWorks, or Pro/ENGINEER.

2.008 - Design & Manufacturing II 2 of 8 The CAD/CAM Labs

LAB EXERCISES
In the next two labs, you will obtain an aluminum disc 3” in diameter and .5” thick (Fig. 1). Inscribe your own
unique pattern on the top with the CNC milling machine (Fig. 2), and turn a custom border/facial profile on the
remainder of the disk with the CNC lathe (Fig. 3).

All exercises will be conducted with a partner - each pair must turn in only one part and will receive a common
grade.1 You and your lab mate may need to meet outside of class in order to complete some of these assignments.
If you are feeling adventurous, you and your lab mate may produce two different paperweights. They will be
graded separately.

Fig. 1 Fig. 2 Fig. 3

During Lab I, you and your lab mate will:

• learn how to write G-code so that you can manually create your own part programs
• run a series of tutorials designed to teach you how to use Mastercam Lathe
• see Mastercam create the G-code for a similar profile as shown in Fig. 3
• use Mastercam to draw the lathe profile of your paperweight (the top drawing can be done by hand or any
software)
• use Mastercam to run a toolpath on the profile
• prepare for next week's lab

During Lab II you and your lab mate will:

• learn how to use Mastercam Mill
• check your pre-prepared handwritten G-code program for the mill portion of your paperweight
• prepare for next week's lab

During Lab III you and your lab mate will:

• finalize the drawings (combining top and side views)
• finalize your pre-prepared handwritten G-code program for the mill portion of your paperweight
• run your program on the CNC mill to inscribe your unique symbol into the center of your disc
• use the CNC lathe to run the profile program to turn/face the shape on your paperweight

1
If you feel that your lab mate is not performing his/her fair share of the work please contact the TA to discuss
grading arrangements.

2.008 - Design & Manufacturing II 3 of 8 The CAD/CAM Labs

DELIVERABLES
This page explains what you must have completed by a week after each lab session. See the "Grading Procedures"
section of the webpage for more details.

DELIVERABLE - Lab I
1) A 2-D drawing of the inscription to be machined on the top of your paperweight. This should be either hand-
drawn on graph paper or computer-drawn and dimensioned.
2) A handwritten G-code program of your unique inscription. A Mastercam Mill generated program is cheating!
3) A separate detailed cross-sectional sketch of the side view showing the profile shape that will be machined on
the lathe. This should also be properly dimensioned and neat.

Things to think about:

• You should have the handwritten program on a 3.5” floppy, or a Zip disk, (100MB, or 250MB) if you work on
it at home so that you will be ready to debug and run at the beginning of Lab III.
• The program should be typed in using Windows Notepad. It must have a filename extension “.txt”.
• Keep in mind that your inscription should fit within a 2.0” diameter circle to allow for machining of the profile
on the perimeter.
• Your milled inscription and profile shape must be unique.
• When dimensioning, be sure to reference everything from the center and top of the disk.
• Don’t forget Z depths!
• Your inscription must have at least one arc or circle - all straight lines are not allowed.
• Remember the diameter of the end mill (it must fit between features) before you try anything too fine and
detailed.
• Remember to consider how the disk will be held in the chuck on the lathe so that you don't machine into the
jaws of the chuck - leave at least .200” of uncut material at the bottom.
• Remember to consider the shape of the bit and the angle from which it will cut.
• An isometric view of your part is purely optional.

DELIVERABLE - Lab II
1) Finalized handwritten G-code for mill.
2) Mastercam generated lathe toolpath for the profile view.

DELIVERABLE - Lab III

1) A completed paperweight, with both the milled inscription and turned profile.
2) A hardcopy of the final handwritten program of the milled inscription if it was changed since Lab II.
3) A Mastercam drawing of the final output of the entire paperweight, with both the top view and the side view on
the same drawing, completely dimensioned.

2.008 - Design & Manufacturing II 4 of 8 The CAD/CAM Labs

APPENDIX A: Producing the Sample Part
Step I: Milled Inscription

In this example the Z0 has been established below the top of the raw stock by .010”. The first tool in the program is
a 1.5” diameter end mill (T11) that will face off the top of the raw stock to establish a plane at Z0. It will remove all
imperfections from the original rough surface to create a uniform flat surface parallel to the machine’s X, and Y
planes. It is important to note that the parallelism of the surface to the machine’s axes is critical for the engraving to
be uniform in depth and width of cut. The engraving tool (T14) is then used to engrave the letters “KC” at a depth
of -.007” into the face, followed by a 1/4” ball end mill (T8) to machine a circular groove around the letters “KC”.

The following is the program. The 2nd column is only to describe what each line, or “block” is doing and is not used
by the control on the machine.

2.008 - Design & Manufacturing II 5 of 8 The CAD/CAM Labs

 Return the X, Y, and Z-axes to a predetermined clearance point for changing tools.
N1M26T11S2000 Install tool T11 (1.5" end mill) for facing top surface, spindle speed 2000RPM
Rapid positioning mode, designate work coordinate system 1, absolute positioning
N2G0G55G90X-2.0Y-1.3 mode, move to the X, and Y values,
N3Z.1 Rapid position Z to the clearance plane, .100" above the part.
N4G1Z0.F5. Linear feed to Z0 at 5" per minute
N5X2.0F10. Linear feed to X value at 10" per minute
N6X2.4Y0. Compound linear feed movement, still at 10" per minute
N7X-2.4 Feed to next point
N8X-2.0Y1.3 Feed to next point
N9X2.0 Feed to next point
N10G0Z.1 Rapid position Z up to clearance plane
Return the X, Y, and Z-axes to a predetermined clearance point for changing tools. Tool
N11M26T14S4000 change, T14. (Engraving tool), spindle speed 4000RPM
Rapid positioning mode, designate work coordinate system 1, absolute positioning
N12G0G55G90X-.375Y.5 mode, move to the X, and Y values,
N13Z.1 Rapid position Z down to clearance plane
N14G1Z-.007F5. Feed Z into part to a depth of -.007" at 5.0" per minute
N15Y-.25F10. Feed Y to -.25 at 10" per minute
N16G0Z.1 Rapid Z up to clearance plane
N17X.375Y.5 Rapid position to start point of next cut
N18G1Z-.007F5. Feed into part
N19X-.375Y.125F10. Feed to next point
N20X.375Y-.25 Feed to next point
N21G0Z.1 Rapid Z up to clearance plane
N22X.515Y.1333 Rapid position to start point of next cut
N23G1Z-.007F5. Feed into part
N24G3X.25Y.243R.375F10. Circular interpolate CCW to the first quadrant of the circle. R is the radius of the circle.
N25X-.125Y-.132R.375 Continue to circular interpolate to the next quadrant
N26X.25Y-.507R.375 Continue to circular interpolate to the next quadrant
N27X.375Y-.4855R.375 Continue to circular interpolate to the end of the circle
N28G0Z.1 Rapid Z up to clearance plane
Return the X, Y, and Z-axes to a predetermined clearance point for changing tools. Tool
N29M26T8S3000 change, T8. (.250 ball end mill)
Rapid positioning mode, designate work coordinate system 1, absolute positioning
N30G0G55G90X.825Y0 mode, move to the X, and Y values
N31Z.1 Rapid Z down to clearance plane
N32G1Z-.125F5. Feed Z-axis into part to a depth of -.125" at 5.0" per minute
N33G3X0.Y.825R.825F5. Circular interpolate CCW to first quadrant of circle, at 5.0" per minute
N34X-.825Y0.R.825 Circular interpolate CCW to next quadrant
N35X0.Y-.825R.825 Circular interpolate CCW to next quadrant
N36X.825Y0.R.825 Circular interpolate CCW to next quadrant
N37G0Z.1 Rapid Z up .100 to clearance plane
N38M26 Return the X, Y, and Z-axes to the clearance point.
N39M30 End program

Step II: Turned Profile

2.008 - Design & Manufacturing II 6 of 8 The CAD/CAM Labs

To view the profile: Launch Mastercam Lathe, from the “MAIN MENU”, select “File”, “Get”, go to the course
locker: X:\2.008\Lathe, open KCL.Mc9. Mastercam will try to find the associated tools, just click “OK”, or
“Cancel” to get through the screens.
To view the toolpath: From the “MAIN MENU”, select “Toolpaths”, “Operations”. In the Operations Manager
window, click “Select All”, then “Backplot”, then select “Run” on the Lathe Backplot menu.

To view the G-code: From the “MAIN MENU”, select “File”, “Edit”, “NC”, open “KCL.NC, this is in the course
locker: X:\2.008\Lathe

APPENDIX B: Programming Machine Tools

A part program is composed of a number of machine tool instructions. These instructions can be commands to: turn
the spindle on, move on an axis, turn the coolant on, select a tool, or execute an entire pattern of movements. A
letter followed by digits is called a ‘word’ and each program line is termed a ‘block’. The commands are executed
in order, one ‘block’ at a time.

Machine tool programming began from a common starting point. The current common character set derives from
the first standard NC machining data communication standard – one-inch wide paper tape. In this standard, letters
are used to define specific program elements:

Address Meaning Address Meaning

O program number F feed rate
N sequence number E thread lead
G preparatory function S spindle speed
X, Y, Z coordinate axis motion T tool number
R arc/corner radius, or rapid plane M misc./machine functions
I absolute center of arc in x-axis J absolute center of arc in y-axis

Due to the power and frequent use of the preparatory functions, CNC control programs are often called G-code.

Logically, different types of machines require different G-code programs. A lathe has different requirements than a
mill or a grinder. In addition, as products have become more advanced and manufacturers have wished to
differentiate their products from their competitors, custom commands have proliferated and made certain programs
incompatible with different machines. It is therefore important to learn which codes are available on which
machines.

COMMONLY USED G-CODE FOR MILLING

G00 rapid linear motion

G01 linear motion at preset feedrate F
G02 circular feed motion - CW
G03 circular feed motion – CCW
G04 dwell for time (P seconds)

G40 cutter compensation off

G41 cutter compensation left
G42 cutter compensation right
G70 inch units
G75 multi-quadrant circles (EZ-Trak machine)
G80 canned drill cycle cancel
G81 standard canned drilling cycle (no pecking)
G83 peck drill cycle
G90 absolute values
G91 incremental values
G92 establish zero point
G55 Workshift 1 (WS1) EZ-Trak machine, Paperweight, and Thermoform mold origin

2.008 - Design & Manufacturing II 7 of 8 The CAD/CAM Labs

G56 Workshift 2 (WS2) EZ-Trak machine, Core mold origin
G57 Workshift 3 (WS3) EZ-Trak machine, Cavity mold origin

S spindle speed (RPM)

F feed rate (IPM)
T tool number
R Height for rapid positioning in drilling cycles, or arc radius value when in G02, or G03

M00 program stop

M01 planned optional stop, can be turned on or off at machine control
M02 end program (Cincinnati Milacron 7vc machine)
M03 spindle on (CW)
M04 spindle on (CCW)
M05 spindle off
M06 change tool
M08 coolant on
M09 coolant off
M13 coolant & spindle on (Cincinnati Milacron 7vc machine)
M25 return Z-axis to machine home (EZ-Trak machine)
M26 return X, Y, and Z axes to a predetermined clearance position for tool change (EZ-Trak)
M30 end program
H tool height offset

Leading zeros are commonly left out to help reduce the size of the programs.

Computer notes:
The computers are networked to the ME server in bldg. 3. Please note that Mastercam writes to C:\temp on
the local hard drives. You must Copy your geometry file “.MC9”, and part program file “.TXT” for the EZ-Trak
mills, or “.NC” for the lathe, to your assigned lab folder on the server, they are safer there and you will be able to
access them from any computer in the lab next time you come in, and others in your work group will be able to find
them as well. The computers also have 250MB Zip drives and will recognize 100MB Zip disks. Make sure you
save your work over the network! The computers are set to automatically log you off after 15 minutes of
inactivity. This time period may change before the labs begin. This automatic logging off will clean the
desktop, and the temp folder. Please keep all files backed up on a floppy disk, or Zip disk. You may create
additional folders within your assigned folder to keep your files organized. Such as a “Mill” folder, and a “Lathe”
folder, with sub-folders under each such as MC9, NC. Refrain from saving your work in your personal network
folder, others in your group will not be able to access the data. Always work out of your assigned lab folder.

There are 2 computers in the shop, Crossshop1 serves the lathe, and Crossshop2 serves the EZ-Trak.

Send the Lathe programs to the appropriate folder within the ‘send’ folder on Crossshop1.
The path: My Network Places\\Entire Network\\Microsoft Windows Network\\Mecheng\\Crossshop1\
Daewoo\Send\

Send the Mill programs to the appropriate folder within the ‘send’ folder on Crossshop2.
The path: My Network Places\\Entire Network\\Microsoft Windows Network\\Mecheng\\Crossshop2\
EZ-Trak\Send\

2.008 - Design & Manufacturing II 8 of 8 The CAD/CAM Labs