CNC Machining

Facing:
Facing is a basic operation carried out in CNC machining, as it is often the first operation that
the workpiece undergoes before any further machining processes and is often used to obtain
the required finish on face of the workpiece/component. More applications of facing include
but are not limited to create precise mating surfaces and removing burrs and imperfections.

In CNC lathe machine, the cutting tool is used to remove material from the outer surface of a
workpiece to create a smooth and flat workpiece. This operation is performed at the end of
the workpiece or along its length to ensure that the face is perpendicular to the axis of
rotation. The workpiece is placed into the chuck/spindle of the lathe machine with the tool
being in the tool holder. We then feed the g-code into the Sinumerik 808d which is
responsible for depth of the cut, feed rate and spindle speed etc. As the lathe rotates the
workpiece, the cutting tool moves along its axis and slowly removes material from the face.
In facing, the tool may be programmed to move either in a straight line or follow a specific
contour/path to fabricate the required shape.

Some advantages of the facing operation are high precision and accuracy, elimination of
human errors, the production of parts with tight tolerances, reduced setup time and improved
safety.

G90 Set absolute programming mode.

G54 Select work offset coordinate system.
G50 S2000 Set maximum spindle speed to 2000 RPM.
T0101 Select tool number 01 and tool offset number 01.
G96 S150 Set constant surface speed (CSS) to 150 SFM
G00 X50 Z10 Rapid move to initial X and Z positions
G01 Z-20 F0.015 Feed moves to facing depth at a feed rate of 0.015 inches per revolution
X30 Move to facing position along the X-axis.
G02 X10 Z-20 R10 Arc move in a clockwise direction from X30 to X10 with a radius of 10
units and continue to Z-20
X50 Z-20 Move back to the starting point.
G00 Z10 Rapid retract to Z10.
G28 U0 Return to home position on the U-axis.
M30 Program end and stop the spindle

G-code:

Grooving:
For grooving in a cnc lathe machine, a cutting tool is used to create a channel or groove on
the workpiece. Grooves can be cylindrical, tapered or custom depending on requirements.
The workpiece is placed into the chuck/spindle of the lathe machine with the tool being in the
tool holder. After feeding and running the program, as the lathe starts to rotate the workpiece,
the cutting tool moves along the axis and removes material, thus forming the groove.
Whether the groove is created in a single pass or multiple depends on the width and the depth
of groove in addition to the limitations of the cnc lathe machine and tool.

An advantage of grooving on the cnc lathe machine is that various groove profiles can be
accommodated, such as straight, tapered, V-shaped, or custom geometries. Thus, a multitude
of parts can be produced.

Parts produced by grooving are commonly used in the aerospace, automotive, oil & gas
industries apart from general manufacturing. It is used to manufacture O-ring seats, keyways,
oil grooves, thread starts and decorative patterns on parts.

G-code:
G90 Set absolute programming mode.
G54 Select work offset coordinate system.
G50 S2000 Set maximum spindle speed to 2000 RPM.
T0101 Select tool number 01 and tool offset number 01.
G96 S150 Set constant surface speed (CSS) to 150 SFM
G00 X50 Z10 Rapid move to initial X and Z positions
G01 Z-20 F0.015 Feed moves to groove depth at a feed rate of 0.015 inches per revolution.
X30 Move to start position of the groove along the X-axis.
G42 D02 Activate tool compensation with a tool radius of 0.02 inches.
G73 U0.1 R0.05 U-depth (0.1 inches), R-approach (0.05 inches)
X20 Move to the end position of the groove along the X-axis.
G01 Z-20 Feed move back to the initial groove depth.
G40 Cancel tool compensation.
X50 Z10 Rapid move back to the initial position
G00 Z10 Rapid retract to Z10.
G28 U0 Return to home position on the U-axis.
M30 Program end and stop the spindle

Turning:
Turning on a cnc lathe machine consists of a rotating workpiece while the cutting tool
removes material from its outer surface. It is usually used to manufacture cylindrical shapes,
such as shafts, rods, and discs.

As the workpiece is rotated by the lathe, the cutting tool moves along the longitudinal axis
and material is removed, thus shaping the workpiece. Turning on a CNC machine offers a
few benefits. In the first place, it gives remarkable accuracy and repeatability, bringing about
consistent and high-quality parts. The CNC control system eliminated of human errors and
variations, guaranteeing that every workpiece meets the ideal determinations. CNC turning
can be performed on various materials including metals, plastics and composites, producing
dimensionally consistent parts of the materials.

G-code:

G21
G90
S1000
F200
M3
G0 X10 Z-5
G1 X20 Z-10
G1 X30 Z-15
G1 X40 Z-20
G0 X50 Z0
M5
M30

Taper turning:
A type of turning, CNC taper turning can be achieved in various ways. The most used method
is to use a compound rest. This allows the cutting tool to be tilted in two axes, which helps
create a tapered surface on the workpiece. Alternatively, a taper attachment can also be used.
It is mounted on the lathe and that allows the cutting tool to be moved in a way that creates a
tapered surface on the workpiece.

Following are some of the benefits of CNC taper turning:

 Accuracy: ideal for producing parts with tight tolerances.
 Versatility: can be used to produce a multitude of parts.
 Speed: higher production rate equates to increased productivity.

G-code:
G90 G28 U0 W0
M06 T1
G00 X50 Z0
G97 S1000 M03
G01 X50 Z-10 F100
G76 P021060 Q100 R100
G01 X18.2 Z-20 F100
G00 X50 Z20
M05 M02
M30

Step turning:
Step turning is another method of turning, and can be used to manufacture straight steps,
tapered steps, and compound steps. In step turning, the cutting tool can be either a single
point tool for straight steps or multi point tools for tapered and compound steps. It has the
same advantages as taper turning.

G-code:
G90 G28 U0 W0
M06 T1
G00 X50 Z0
G97 S1000 M03
G01 X50 Z-10 F100
G76 P021060 Q100 R100
G01 X18.2 Z-20 F100
G00 X50 Z20
M05 M09
M30

Cutoff operation:
The cutoff operation in a cnc lathe machine is a process used to remove the end of a
workpiece. The cutoff tool is usually a single point tool positioned as such that it is aligned
with the axis of the workpiece. The required length is removed by feeding the tool into the
workpiece. Special care must be taken to ensure that the feed rate is adequately slow to
prevent the tool from chattering (which can lead to a poor surface finish).

G-code:
G90 G00 G17 X0 Z0
G01 M08 F100 S1000
G01 Z-10
G01 X100
G01 Z0
M09
M30

Threading:
Threading is the process of cutting a helical ridge of uniform section on the workpiece. This
is performed by taking successive cuts with a threading toolbit the same shape as the thread
form required.

There are two main types of threading operations on a CNC lathe:

 External threading: This is the process of cutting threads on the outside of a

workpiece.
 Internal threading: This is the process of cutting threads on the inside of a workpiece.

Threading operations can be performed using a variety of tools, including:

 Single-point threading tools: These are the most common type of threading tool. They
are made of high-speed steel (HSS) or carbide, and they have a single cutting edge.
 Thread-forming tools: These tools are used to create threads that have a smooth,
uniform finish. They are made of HSS or carbide, and they have multiple cutting
edges.
 Thread-cutting tools: These tools are used to create threads that have a sharp, accurate
finish. They are made of HSS or carbide, and they have multiple cutting edges.

Threading is a versatile tool that can be used to cut a variety of threads. It is a

common operation in many industries, including manufacturing, machining, and
fabrication.

G-code:
 G90 G00 G17 X0 Z0
G01 M08 F100 S1000
G01 Z-10
G97 G33 P0123456789 D0.3 M03
G01 Z-20
G01 X100
G01 Z0
M09
M30

EDM die sinking:

EDM die sinking is a process which involves using electrical discharge machining to create
various shapes in metal. An electric spark is created between a tool and a workpiece, thus
melting and vaporizing the metal at the point of contact. It is commonly used to manufacture
dies and molds for plastic injection molding, apart from being used for cutting, drilling and
engraving. EDM die sinking is a safe process when proper safety procedures are followed.
However, there are some potential hazards associated with the process, such as electrical
shock and burns. It is important to be aware of these hazards and to take steps to avoid them.
Here are some safety guidelines to follow when using EDM die sinking:
 Always wear personal protective equipment (PPE), such as safety glasses, gloves, and
a face shield.
 Make sure the work area is well-ventilated to prevent the buildup of fumes.
 Do not operate the machine if it is damaged or malfunctioning.
 Follow the manufacturer's instructions for safe operation.

EDM wire cut:

Also known as wire cut EDM, wire cutting is a subtractive manufacturing uses a thin,
electrically conductive wire to cut and shape a workpiece. The workpiece is submerged in a
dielectric fluid, which often deionized water. When the workpiece is close enough to the
wire, electrical discharge will occur which results in vaporization of material. This procedure
is continued until the desired shape/design is achieved. This method is a very precise one and
may be used to cut complex shapes which have tight tolerances. Another advantage of this
method is its ability to cut through different materials such as steel, stainless steel, and
titanium.