Manual Clt100 Slt100

HYTECH
ISO 9001:2008
Since 1992
CNC LATHE
OPERATING MANUAL
HYTECH EDUCATIONAL EQUIPMENT CNC Lathe Trainer
support@hytecheducation.net / sales@hytecheducation.com
Table of Contents
1.0 INTRODUCTION ......................................................................................................................................................................................................... 7

1.1 PC Based Machines Vs. ‘Hytech’ PLC Based Machines ............................................................................................... 8
1.2 AIM OF HYTECH CNC TRAINER ................................................................................................................................................................ 10
1.3 Basic Principle ................................................................................................................................................................................................................ 10
1.4 NC Organization ......................................................................................................................................................................................................... 10
1.4.1 Program Preparation Methods................................................................................................................................................... 10
1.5 Advantages of CNC Machines ..................................................................................................................................................................13
1.7 SAFETY PRECAUTIONS ......................................................................................................................................................................................13
2.0 Technical Specifications ................................................................................................................................................................................ 15
2.1 Model: SLT 100 Servo........................................................................................................................................................................................... 15
2.2 Model: SLT 150 Servo ............................................................................................................................................................................................17
2.3 Model: CLT 100 ............................................................................................................................................................................................................. 19
2.4 Model: NLT 90 ............................................................................................................................................................................................................... 21
3.0 Overview of Industrial Machine Operating Panel ( MOP) ..................................................................................... 23
3.1 Detailed functioning of Hytech Industrial MOP ...............................................................................................................24
4.0 Switching ON and Switching OFF the machine: ............................................................................................................... 27
4.1 Switching ON the machine:........................................................................................................................................................................ 27
4.2 Switching OFF the machine: ..................................................................................................................................................................... 27
5.0 JOG Mode: .................................................................................................................................................................................................................. 28
5.1 JOG Menu Functions ........................................................................................................................................................................................... 29
6.0 AUTO Mode: ............................................................................................................................................................................................................. 40
6.1 Simulation Mode ......................................................................................................................................................................................................42
6.1.1 How to simulate a program in simulation mode:..............................................................................................42
6.2 MACHINING Mode .................................................................................................................................................................................................45
6.2.1 How to simulate a program in Machining Mode: ............................................................................................ 46
6.3 Switching between ‘JOG’ mode and ‘AUTO’ mode: ................................................................................................... 46
7.0 CNC Coordinate System ............................................................................................................................................................................. 48
7.1 Machine coordinate system (MCS):................................................................................................................................................ 48
7.2 Workpiece coordinate system (WCS) ...........................................................................................................................................49
7.3 Clamping the workpiece ............................................................................................................................................................................... 50
7.4 Taking Tool Offset: .................................................................................................................................................................................................. 51
7.4.1 Taking Tool Offset: .................................................................................................................................................................................... 52
7.4.2 Taking Work Offset: ................................................................................................................................................................................. 59
7.5 Coordinate Geometry ........................................................................................................................................................................................62
7.5.1 REAL NUMBER SYSTEM.....................................................................................................................................................................62
7.5.2 RECTANGULAR COORDINATE SYSTEM........................................................................................................................... 63
7.5.3 Axes and Planes ............................................................................................................................................................................................ 63
7.5.4 MACHINE GEOMETRY ........................................................................................................................................................................66
8.0 CNC Programming:............................................................................................................................................................................................ 68
8.1 BASIC PROGRAMMING TERMS ............................................................................................................................................................. 68
Page 2 of 234
8.2 PROGRAMING FORMATS ............................................................................................................................................................................... 70

8.3 WORD ADDRESS FORMAT ........................................................................................................................................................................... 70
8.4 FORMAT NOTATION ............................................................................................................................................................................................. 72
8.5 PROGRAMMING TIPS .......................................................................................................................................................................................... 74
8.6 Absolute/incremental dimensioning: G90, G91 ................................................................................................................. 75
9.0 MECHANICAL SYSTEM................................................................................................................................................................................... 76
9.1 Bed ............................................................................................................................................................................................................................................ 76
9.2 Saddle, &Slide .............................................................................................................................................................................................................. 76
9.3 Spindle Head.................................................................................................................................................................................................................. 76
9.4 Axes Drive System ................................................................................................................................................................................................ 76
9.4.1 Stepper Motors ........................................................................................................................................................................................... 76
9.4.2 Servo Motors ..............................................................................................................................................................................................77
9.5 Spindle Drive System: .........................................................................................................................................................................................77
9.6 BALL SCREW ..................................................................................................................................................................................................................77
9.6.1 Lubrication: ..........................................................................................................................................................................................................77
9.6.2 Dirt Protection: ............................................................................................................................................................................................ 78
9.6.3 Radial Load and Moment Load ............................................................................................................................................... 78
9.6.4 Mounting ............................................................................................................................................................................................................. 78
9.6.5 Precautions ....................................................................................................................................................................................................... 78
Servo Motors Vs Stepper Motors ..................................................................................................................................................................... 79
10.0 CNC CUTVIEWER SOFTWARE ................................................................................................................................................................. 87
10.1 CutViewer Features .............................................................................................................................................................................................. 87
10.1.1 Full 3D Simulation, not just a toolpath viewer ..................................................................................................... 87
10.1.2 Collision detection prevents catastrophes......................................................................................................... 87
10.1.3 Reads all common G code formats .............................................................................................................................. 88
10.1.4 Use any kind of tool ......................................................................................................................................................................... 88
10.1.5 Measure the finished part without having to cut a thing ...............................................................89
10.1.6 Built-in G code editor....................................................................................................................................................................89
10.1.7 Machining Mode / Simulation Mode ................................................................................................................................89
10.1.8 Other CutViewer Features:......................................................................................................................................................90
10.2 CUTVIEWER TURN SOFTWARE ..............................................................................................................................................................90
10.2.1 Running CutViewer ............................................................................................................................................................................. 91
10.2.2 Command Bar Functions: ........................................................................................................................................................... 93
10.2.3 Tool and stock definition ........................................................................................................................................................... 95
10.2.4 Tool Definition..........................................................................................................................................................................................98
10.2.5 Editing .............................................................................................................................................................................................................. 102
10.2.6 Zooming .........................................................................................................................................................................................................103
10.2.7 View Rotation ........................................................................................................................................................................................ 104
10.2.8 View Panning.......................................................................................................................................................................................... 104
10.2.7 Settings .......................................................................................................................................................................................................... 104
10.2.8 Customizing.............................................................................................................................................................................................. 106
Creating new NCI files...................................................................................................................................................................................................... 106
Page 3 of 234
10.2.9 Custom Control Conversion................................................................................................................................................ 109

10.2.10 Supported codes for Fanuc F0TA and F10TA, F11TA ............................................................................110
11.0 GETTING READY WITH SOFTWARE: ................................................................................................................................................ 112
11.1 About Cutviewer software:....................................................................................................................................................................... 113
11.2 FILE MENU:- .................................................................................................................................................................................................................... 114
11.3 EDIT MENU :- ............................................................................................................................................................................................................... 114
11.4 VIEW MENU:- .............................................................................................................................................................................................................. 115
11.5 RUN MENU:- ................................................................................................................................................................................................................. 116
11.6 ZOOM MENU:- ........................................................................................................................................................................................................ 116
11.7 PAN MENU:- ................................................................................................................................................................................................................. 116
11.8 ROTATE MENU:- ..................................................................................................................................................................................................... 117
11.9 SETUP MENU:- ......................................................................................................................................................................................................... 117
11.10 MODE: .................................................................................................................................................................................................................................. 117
11.11 MEASUREMENTS.................................................................................................................................................................................................... 117
11.12 HELP MENU:- ............................................................................................................................................................................................................. 118
12.0 CNC PROGRAMMING G & M CODES ............................................................................................................................................ 119
12.1 G Code List ...................................................................................................................................................................................................................... 119
12.2 M Code List: ................................................................................................................................................................................................................. 120
13.0 Description of G Codes ................................................................................................................................................................................ 121
13.1 Linear interpolation .............................................................................................................................................................................................. 121
13.1.0 Linear interpolation with rapid traverse: G0 .......................................................................................................... 121
13.1.1 FeedRate ............................................................................................................................................................................................................... 121
13.1.2 Linear interpolation with feedrate: G1............................................................................................................................ 121
Example 1: .................................................................................................................................................................................................................................. 122
13.1.3 Circular interpolation: G2, G3 .................................................................................................................................................... 123
Example 2: ................................................................................................................................................................................................................................. 127
Example 3: .................................................................................................................................................................................................................................128
13.1.4 Threading (G32):..........................................................................................................................................................................................129
Example 4:.................................................................................................................................................................................................................................129
Example 5: .................................................................................................................................................................................................................................130
Example 6:.................................................................................................................................................................................................................................. 131
Example 7: ................................................................................................................................................................................................................................. 133
Example 8:................................................................................................................................................................................................................................. 136
Example 9: ................................................................................................................................................................................................................................. 137
Example 10: .............................................................................................................................................................................................................................. 139
Example 11: ............................................................................................................................................................................................................................... 145
13.1.5 G04 - PROGRAMMED DWELL .................................................................................................................................................152
13.1.6 G20 - INCH PROGRAMMING .....................................................................................................................................................152
13.1.7 G21 - METRIC PROGRAMMING ...............................................................................................................................................152
13.1.8 G28 - AUTO. RETURN TO REF. POINT ...............................................................................................................................152
13.1.9 G70 - FINISHING CYCLE .................................................................................................................................................................152
13.1.10 G71 – STOCK REMOVAL IN TURNING ............................................................................................................................. 153
Page 4 of 234
Example 12 (G71): - ......................................................................................................................................................................................................... 154

13.1.11 G72 – STOCK REMOVAL IN FACING ........................................................................................................................ 157
Example 13: .............................................................................................................................................................................................................................. 158
13.1.12 G73 PATTERN REPEATING CYCLE: ............................................................................................................................... 161
Example 14: ..............................................................................................................................................................................................................................162
13.1.13 G74-PECK DRILLING CYCLE............................................................................................................................................... 165
Example 15:.............................................................................................................................................................................................................................. 166
13.1.14 G75 (GROOVING CYCLE): ..................................................................................................................................................... 168
Example 16 (Grooving Cycle):.......................................................................................................................................................................... 168
13.1.15 G76- TAPER THREADING CYCLE ....................................................................................................................................... 171
Example 17 (Strait thread): .................................................................................................................................................................................... 171
Example 18 (G76 Cycle):........................................................................................................................................................................................... 174
13.1.16 G90 –DIAMETER CUTTING CYCLE .............................................................................................................................. 178
Example 19:............................................................................................................................................................................................................................... 179
13.1.17 G92 -THREAD CUTTING CANNED CYCLE ..........................................................................................................182
Example 20: .............................................................................................................................................................................................................................182
13.11.18 G94 CANNED CYCLE FOR FACING .............................................................................................................................. 185
Example 21:.............................................................................................................................................................................................................................. 185
Example 22 (G94 CANNED CYCLE FOR FACING WITH TAPER): ........................................................................... 186
13.1.19 G96 - CONSTANT SURFACE SPEED ON.............................................................................................................. 189
Example 23:............................................................................................................................................................................................................................. 190
14.0 Description of M Codes ..............................................................................................................................................................................192
14.1 M00 – PROGRAM HALT ..............................................................................................................................................................................192
14.2 M01 - OPTIONAL PROGRAM STOP................................................................................................................................................192
14.3 M02 - PROGRAM END ..................................................................................................................................................................................192
14.4 M03 - SPINDLE ON CLOCKWISE......................................................................................................................................................192
14.5 M04 - SPINDLE ON ANTICLOCKWISE .......................................................................................................................................192
14.6 M05 - SPINDLE STOP ..................................................................................................................................................................................... 193
14.7 M07 - COOLANT NO. 1 ON ....................................................................................................................................................................... 193
14.8 M08 - COOLANT NO. 2 ON ..................................................................................................................................................................... 193
14.9 M09 - COOLANT PUMPS OFF ............................................................................................................................................................. 193
14.10 M13 – SPINDLE CLOCKWISE & COOLANT ON ............................................................................................................... 193
14.11 M14 – SPINDLE ANTICLOCKWISE & COOLANT ON................................................................................................. 193
14.12 M30 - END OF PROGRAM ......................................................................................................................................................................... 194
18.13 M98 – SUBROUTINE CALL ...................................................................................................................................................................... 194
15.0 Dos and DONTs ................................................................................................................................................................................................... 195
16.0 CNC Lathe Maintenance ......................................................................................................................................................................... 196
16.1 Controller related: .................................................................................................................................................................................................196
16.2 Lathe related : ..........................................................................................................................................................................................................196
16.3 Electrical Maintenance.................................................................................................................................................................................. 197
16.4 Conditional Checks: ......................................................................................................................................................................................... 198
16.4.1 Stabilizer ..................................................................................................................................................................................................... 198
Page 5 of 234
16.4.2 Power supply ........................................................................................................................................................................................ 198

16.4.3 VFD .................................................................................................................................................................................................................... 198
16.5 General Issues:....................................................................................................................................................................................................... 198
16.6 Earthing Requirements of Hytech CNC Machines with Servo Motors .............................................199
16.7 Necessary Earthing Arrangements for Servo motor based machine: ..............................................200
16.8 Earthing Requirements of Hytech CNC Machines with Stepper Motors ....................................200
17.0 I/O Lines for CLT 100 ..................................................................................................................................................................................... 202
18.0 GLOSSARY OF TERMS ................................................................................................................................................................................. 203
19.0 Contact Details: ................................................................................................................................................................................................. 234
Page 6 of 234
1.0 INTRODUCTION
‘HYTECH’ is the name associated with CNC Trainers since 1992. We have supplied 1,000+
INDEGENIOUS CNC TRAINERS to more than 800 Educational Institutes all over India. More than
30,000 students all over India are trained on Hytech Trainers per year.
We are proud to announce that we are now authorized manufacturers and suppliers of CNC
machines to ‘SKILL DEVELOPMENT PROJECT’ OF GOVT. OF INDIA. Till date, we have established
9 CNC Skill development centers for Govt. of India project.
Our CNC Trainer machines are equipped with Servo Motor technology which is much more
advanced than stepper motor based technology generally used in CNC trainer machines.
Servo motors from Siemens / Mitsubishi can achieve the resolution of 1 micron and Rapid feed
rate of 10,000 mm/min.
We have successfully developed and manufactured indigenous ‘Flexible Manufacturing

System’ based on PLC technology. Our machines can be directly converted into FMS (Visit our
website www.hytecheducation.in to see FMS / CNC Lathe / Mill Videos).
We have also established collaboration with MasterCAM (Onward Technologies) and BobCAD
USA. CAM programs generated from MasterCAM, BobCAD and any other leading CAD CAM
software can be executed on Hytech CNC Trainer machines.
‘HYTECH’ follows the tradition of latest technology & provides strong service support through
efficient network of Dealers & Service Engineers all over India.
‘HYTECH’ offers all types of CNC Machines such as Trainers, Semi-Production Machines and
Production Machines with FANUC / SIEMENS / MITSUBISHI controller. We also offer total
solution to CAD-CAM lab with Latest CAM Software and AMC Contracts.
‘Hytech’ is also a reputed manufacturer of Robotic Arms required for Robotic / Automation
Lab. Our Robots are based on PLC technology which can be directly interfaced with our
machines.
We are proud to have opened our CNC Training Center for lab assistants. You can train your
lab assistants at our Pune Training Centre at FREE OF COST.
COME; JOIN US TO EXPERIENCE THE NEW EDGE IN CAD-CAM TECHNOLOGY.
Page 7 of 234
1.1 PC Based Machines Vs. ‘Hytech’ PLC Based Machines
In the early 1990s, when CNC technology was taking shape, PC based control system was the
only control system available in CNC Trainer technology. Being readily available and open to
almost all softwares, PC based system became popular all over the world. The popularity of PC
based system was largely credited to the unavailability of any other option rather than its
technical superiority. Continuous breakdowns and highly unexpected problems clearly
indicated the need of much better and reliable technology.
In the late 1990s, breakthrough was made when PLCs started taking place of PCs in motion
control applications. All of the giants in motion control such as Siemens, Fanuc, Huss
immediately transformed to PLC based technology. Although a little expensive than PC based
control, PLC based controls were highly efficient and reliable.
Today, 99% of the CNC control manufacturers are using PLC based controls.
PLC based controls with PCs as Human – Machine Interface (HMI), provides best possible
solution especially in CNC trainer machines. The communication between machine and
controller is an Ethernet communication which allows data to be transferred with 0 loss. In
case of PC based machines, communication is through RS 232 / RS 485 port which limits the
speed as well as distance of data transfer due to very high losses.
PC based controls are totally dependent on PCs. Since PCs are powered directly from the
power source (230V, Single Phase, AC), any fluctuation / spike in the power source is directly
transferred to PCs which is eventually transferred to CNC machine. In a developing country
like India, which experiences around 295 power cuts in a year on an average in any city, life of
a computer is considered to be around 2 years. Naturally, life of PC based CNC systems is
around 2 years after which they need a complete overhaul.
PLC has its own power supply which is generally of 24V DC. Any fluctuation in main power
supply is not transferred to PLC. Since PC in PLC based system is only used as an HMI, we can
change PC at any time with no repercussions on CNC control. On an average, life of a PLC
based system is around 10 years.
Since PLC systems work on 24V DC, heat generated is only 10% as compared to the heat
generated in PC based systems. Hence there is no problem of heat dissipation even in places
of high temperatures / humidity. PLCs can work efficiently even in places where PCs are not
able to operate without ample cooling.
One of the most important advantages of PLC based system is remote operation. Since PLCs
operate on Ethernet communication, they can be operated remotely from anywhere in the
world. ‘Hytech’ Service Engineer can trace the exact problem in a machine working in Malaysia
and resolve the issue without leaving his own office in Pune, India.
Page 8 of 234
Comparison of PLC Based System and PC Based System:
Characteristics PLC Based System PC based system
Cost The cost of PLC based system is high since PC based systems are much cheaper
the technology is much advanced and since technology from 1990s is used
computer is used as an HMI
Durability Industrially hardened and extremely stable Limited to the durability of windows
(no Windows limitations) or any other operating system
Reliability Failure rate of PLCs is less than 1% over its Failure rate of PCs is around 20 - 35%
average expected life over its average expected life
Life Life of a PLC is around 10 to 15 years Life of a PC is around 2 to 3 years
Servo Motors Servo motors can be operated by a PLC Servo motors cannot be operated by
system as maximum pulses that can be a PC based system since maximum
transferred by a PLC are 92,000 pulses/sec pulses that can be transferred by a PC
based system are only 10,000
pulses/sec
Mode of Ethernet communication RS 232 / RS 485 Communication

Communication
Distance of Data Can travel huge distances. Mode of Upto 3 meters
Transmission communication / data transfer is exactly
similar to that used in broadband internet
transmission.
FMS Compatibility Fully compatible. Single PLC can operate Not possible since one computer
32 other PLCs. That means, one control cannot control / operate another
system can operate 32 CNC machines at a computer
time
Heat Generated Very low since operates on 12V / 24V DC Heat generated is very high since PC
supply operates on 230V AC supply
Use in Industry Most of the CNC control manufacturers Mostly used in trainer machines only.
such as Siemens, FANUC, Huss use PLC No real use in industrial applications
technology
I/O Capacity DI: 256, DO: 256 DI:32, DO:32

RI: 64, RO: 64
Maximum Input Speed 920 KHz 10KHz
Interpolation Up to 4 Axes simultaneous interpolation Simultaneous interpolation of more

than 2 axes is not possible
Page 9 of 234
1.2 AIM OF HYTECH CNC TRAINER
 Acquire basic knowledge of CAD and CAM
 To get familiar with basic operations of CNC Machines
 To understand theoretical as well as practical applications of CNC Machines
 Understand programming of CNC Machines
 Understand basic working principles of CNC Machines
 Understand programming language / nomenclature required for different popular

controllers such as Siemens / Fanuc
1.3 Basic Principle
The basic principle of controlling machine tools by numerical control has remained unchanged
since its invention. However, the number of functions and tasks allocated to the controller has
grown steadily over the years & now offer a high level of automation.
Specifically, automatic machine tools are programmed to perform an ordered sequence of

events at a predetermined rate & sequences to produce a piece part with entirely predictable
results & physical parameters.
A programmed path is loaded into the machine’s computer by the operator and then
executed.
NC technology has been one of manufacturing’s major developments in the past fifty years. It
has not only resulted in the development of new techniques & the achievement of higher
production levels but also has helped to increase product quality and stabilize manufacturing
costs.
1.4 NC Organization
1.4.1 Program Preparation Methods
Part programming of NC production machines comprises the collection of all data required to
produce the part, the calculation of a tool path along which the machine operations will be
performed, and the arrangement of those given and calculated data in a standard format,
which could be converted to an acceptable form for a particular machine control unit.
Different methods can be employed in the preparations of NC programs depending upon how
a particular company has organized its NC programming, and also depending on that
additional data processing aids are available. They are :
Page 10 of 234
 Programming in the planning department
 Programming in the workshop
 Manual programming
 Computer assisted programming
 Higher level programming languages
1.4.1.1 Programming in the Planning Department
This method is advantageous where;
 The existing CNC systems are complicated
 The work pieces have complex geometry
 There are many similar CNC machines in the plant
 Workshop personnel are qualified.
 Programming systems can be utilized.
1.3.1.2 Workshop Programming
Many CNC machines are designed for workshop programming as a fundamental concept, and
there can be wide differences in how the machines are operated. To support the operator in
the workshop, most CNC systems feature operator guidance. When such guidance is
available, the screen shows consecutively or simultaneously, in any situation, those functions
that can be selected. When inputting programs, it is particularly useful that the screen not
only shows the program instruction input, but also the possible supplementary functions.
(Coordinates, feed rates, etc.)
This programming can be used when
 The CNC machines are easy to operate
 The work pieces have similar geometry
 There are only a few CNC machine in the plant
 Rapid fault elimination and program optimization are essential.
Page 11 of 234
1.4.1.3 Manual Programming
In this method the necessary program information is taken directly from workpiece drawing
and set down in the form of program blocks which are then input the control system (possibly
by punched tape). We speak of manual programming, example, if programming is carried out
in the programming language of the CNC system (i.e. a control plane followed established
standards) - regardless of whether programming is carried out in the workshop or in the
planning department. Many programming is suitable only to develop part programs for 2D and
2-1/1 D machining.
1.4.1.4 Computer Assisted Programming
Preparing NC programs for complicated parts with a programming language following

established standards can involve considerable effort and expenditure. Thus number of
program blocks may be very high which makes the program less clear prone, and difficult to
modify. In addition, difficult mathematical calculations may be required which can only be
carried out with further aids such as books of mathematics, calculator etc.
Computer assisted part programming system has two components pre processor and, post
processor.
A pre-processor is software consisting of a specially structured set of symmetrical rules and

conventions by means of which the programmer communicates the desired information to
the computer system. All the necessary calculations for missing points, auxiliary points, cut
distribution, speed etc. are then carried out automatically by the computer. The processor
generates data on cutter location and machine motion data). NC programs prepared in this
way are issued either in the form of punched tape as diskettes. Alternatively, they can also
be sent directly to the CNC machine through “on-line” data connection.
A post processor is a computer program which accepts the CL data together with machining
data such as speeds, feeds and tolerances. It generates the machine specific part program to
produce the part on a specific CNC machine tool.
Using higher programming languages makes it possible to program the machining workpiece
independently of a particular CNC system. However, every control type requires its own post
processor so that a suitable NC program is produced.
Among the several part programming languages, APT (Automatically programmed tools) is the
most widely used one. It employs four types of statements to generate the part program. They
are:-
 Geometry Statements
 Motion statements,
 Auxiliary statements, and

Page 12 of 234
 Post processor statement.
1.5 Advantages of CNC Machines
- Elimination of operator errors
- Ease of doing complicated jobs
- Longer tool life
- With the assistance of CAD / CAM Softwares, feasibility of machining can be checked
out brfore actual machining
- Exact estimation of cycle time
- Less dependence on Skilled Labor
- Reduction in total rejection
- High repeatability
- High Accuracy
1.6 Operational Safety
‘HYTECH’ Lathe has been engineered for operational safety. The entire machine is covered to
eliminate damage from metal chips & to prevent an insecurely-clamped workpiece being
thrown out during operation. However with machine of this nature, serious accident may
occur owing to improper or careless operation.
It is strongly suggested to read this manual carefully before operating the machine.
Improper operation or unauthorized uses may lead to a malfunction or an accident. Thus, if a

particular operation is not documented in the “HYTECH” manual as authorized usage of the
equipment, and you are interested to operate then it will be assumed that this is an
unauthorized or improper usage with potential danger & should be avoided.
Use of the machine by unauthorized / not trained personnel will always bear the risk of dmage
/ accident.
1.7 SAFETY PRECAUTIONS
1. Do not machine the job on the trainer machine until simulation is first checked and the
same job is run in dry mode without actual cutting process. Ideal process / sequence is
mentioned below:
Page 13 of 234
- Run the program in simulation mode. Check whether the job is performed in intended
way.
- Run the program in machining mode without any workpiece mounted in the chuck.
This will ensure if the programming is done within practical limits.
- Finally, carry out the machining process on the raw material.
2. Operating the trainer with incorrect data may result in damage to the workpiece &
trainer or injury to the user.
3. Before attempting to perform programming, read this manual carefully to operate the
trainer safely.
4. Coordinate setting is very important factor while operating the CNC trainer. Incorrect
coordinates may damage the tool / machine / user.
5. Before giving numerical i/p command determine the current position of the tool &
workpiece & ensure the axis, direction & command have been specified correctly & the
entered values are valid.
6. Operator should always be close to the machine when the machining is in progress.
Page 14 of 234
2.0 Technical Specifications
2.1 Model: SLT 100 Servo
SLT 100 Servo

Machine Details:
Bed Type Flat / 45 Degrees Slant
Keyboard Type Fanuc Emulated / Standard
Chuck Size 100 mm (Dia)
Chuck Type Hydraulic / Manual
Maximum Turning Diameter 50 mm
Maximum Turning Length 250 mm
Center Height 100 mm
Swing over Cross Slide 80 mm
Swing Over Bed 200 mm
Distance between Centre 320 mm
CNC Controller Details:
Controller Hytech with CutViewer-United Kingdom
Control System PLC Based Control System
Operating Software CutViewer - United Kingdom
Accuracy:
Positioning 0.005 mm
Repeatability +/- 0.005 mm
Resolution 0.001 mm
Spindle:
Spindle Motor AC Motor
Spindle Motor Capacity 2 HP
Spindle RPM 100 to 4000 RPM with VFD
Spindle Nose Taper A 2-3 / MT 3
Hole Through Spindle 20 mm
C Axis (Optional) C Axis with Brake
Axes:
Servo Motor with Servo Drives
Axis Motor and Drive
(Mitsubishi / Siemens)
X Axis Travel 100 mm
Z Axis Travel 300 mm
Ball Screw X / Z Ø25 x 5 - C3 Class
Programmable Feed Rate 0 to 10,000 mm/min
Rapid Travel 10,000 mm/min
Turret and Tooling:
Turret Type Automatic
Number of Stations 4/8
Tool Cross Section 16 mm x 16 mm
Boring Bar Size 16 mm
Tailstock:
Tailstock Base Stroke 200 mm
Page 15 of 234
Tailstock Quill Stroke 100 mm

Tailstock Actuation Hydraulic / Manual / Electrical
Miscellaneous:
Lubrication Automatic
Coolant Automatic
FMS Compatibility Provided
Dimension in mm 1480 x 800 x 1200 mm
Power Supply 415V, +-2% 50 Cycles, 3 Phase
Page 16 of 234
2.2 Model: SLT 150 Servo
SLT150 Servo
Machine Details:
Keyboard Type Fanuc Emulated / Manual
Chuck Type Hydraulic
Accuracy:
Repeatability +/- 0.005 mm
Resolution 0.001 mm
Spindle:
Spindle Motor AC Servo
Spindle Motor Capacity 3.7 KW / 5 HP
Spindle Nose Taper A 2-5
Axes:
Servo Motor with Servo Drives
(Mitsubishi / Siemens)
Programmable Feed Rate 0 to 10,000 mm/min
Turret and Tooling:
Tailstock:
Page 17 of 234
Miscellaneous:
Coolant Automatic
Power Supply 415V, +-2% 50 Cycles, 3 Phase
Page 18 of 234
2.3 Model: CLT 100
CLT 100
Machine Details:
Keyboard Type Fanuc Emulated / Standard
Chuck Type Hydraulic / Manual
Accuracy:
Repeatability +- 0.015 mm
Resolution 0.010 mm
Spindle:
Axes:
Stepper Motor with Stepper Drives imported
from Singapore
Feed Rate 0 to 1,200 mm/min
Turret and Tooling:
Tailstock:
Page 19 of 234
Miscellaneous:
Coolant Automatic
Real Time Toolpath Simulation Provided
Power Supply 230V, Single Phase
Page 20 of 234
2.4 Model: NLT 90
NLT 90
Machine Details:
Bed Type Flat
Keyboard Type Standard
Chuck Type Manual
Center Height 90 mm
Accuracy:
Repeatability +- 0.020 mm
Resolution 0.010 mm
Spindle:
C Axis (Optional) Mnot Provided
Axes:
Stepper Motor with Stepper Drives imported

from Singapore
X Axis Travel 60 mm
Feed Rate 0 to 800 mm/min
Rapid Travel 800 mm/min
Turret and Tooling:
Manual (Option of 8 Station Automatic Turret
Turret Type
Available)
Tailstock:
Page 21 of 234

Tailstock Actuation Manual
Miscellaneous:
Coolant Automatic
Real Time Toolpath Simulation Provided
Power Supply 230V, Single Phase
Page 22 of 234
3.0 Overview of Industrial Machine Operating Panel ( MOP)
Emergency Stop Indication

Machine ON Indication
Machine ON Switch Emergency Switch
Turret Home Machine ON
JOG Turret Index

AUTO Mode Coolant ON
Spindle STOP Move in Z+ Direction
Spindle Run in CCW Move in Y+ Direction
Limit Switch ON Move in Rapid
Cycle Stop / Pause Move in X+ Direction
Cycle Start Move in Z- Direction
RESET
Lubrication ON
Move in X+ Direction
Reference Point Spindle Run in CW Move in X- Direction
Page 23 of 234
3.1 Detailed functioning of Hytech Industrial MOP
Machine ON / OFF Switch:

This is the switch which is operated for switching ON or switching OFF the machine. This is
the main switch of the machine. During Machine ON condition, Machine ON indication will
be displayed on MOP.
Machine ON Soft switch:
After machine ON switch in switched ON, machine can be switched ON or OFF with the
help of this soft button.
Machine ON Indication:
Once the Machine ON switch is switched ON, Machine on Indication will be displayed.
Emergency Switch:
Emergency switch is provided to stop the machine operation at any desired time. In case
of stepper motor based machines, releasing the emergency switch will bring the machine
to its operational state. In case of servo motor based machine, user needs to switch OFF
and switch ON the three phase supply after releasing the emergency switch to make
machine operational.
Emergency ON indication:
Once Emergency switch is pressed, it will be indicated on Emergency ON indication.
JOG Mode:
Pressing this button will activate JOG mode. User needs to start cutviewer software first
before operating this button. As soon as the JOG button is pressed, JOG window will open
in the software.
Auto Mode:
Pressing this button will activate Auto Mode. Auto mode is specifically provided for the
operation of CAM programs. Cycle start button will operate only if the Auto mode is
activated.
Reference Mode:
This button is provided for automatic referencing of the machine. To activate Reference
mode, first activate JOG mode. That means, reference mode will not activated if user
presses Reference button in Auto mode. (Note: This facility is not provided in NLT 90
model in CNC Lathe trainers and NMT 225 model of CNC Mill trainer)
Turret Index:
Operating this button will index the turret by one (Tool) position. This button will operate
only in JOG mode. That means pressing this button in Reference or Auto mode will not
result in anything.
Coolant ON:
Page 24 of 234
This button will start the coolant flow. This button will operate in any of the three modes
of machine namely; JOG mode, Reference mode and Auto mode.
Spindle Run in Clockwise Direction:
This button will start the spindle rotation in clockwise direction. This button will operate
only when the machine is in JOG mode.
Spindle Run in Counter Clockwise Direction:
This button will start the spindle rotation in counter clockwise direction. This button will
operate only when the machine is in JOG mode.
Spindle Stop:
This button will stop the spindle rotation in JOG mode.
Limit Switch Activated:
Limit switch indication will be shown on MOP in case if any of the hardware limit switches
are activated.
Move in X+ Direction:
This button will initiate the X Axis movement in +ve direction. This button will be
operational only in JOG mode.
Move in X- Direction:
This button will initiate the X Axis movement in -ve direction. This button will be
Move in Y+ Direction:
This button will initiate the Y Axis movement in +ve direction. This button will be
Move in Y- Direction:
This button will initiate the Y Axis movement in -ve direction. This button will be
Move in Z+ Direction:
This button will initiate the Z Axis movement in +ve direction. This button will be
Move in Z- Direction:
This button will initiate the Z Axis movement in -ve direction. This button will be
Rapid:
Pressing this button will make the axes move in Rapid in JOG mode. User has to keep this
button pressed when he intends to move axes in rapid in JOG mode.
Cycle Start:
This button will start the program / operation in Auto mode. This button will operate only
in Auto mode.
Page 25 of 234
Cycle Stop / Pause:

This button will pause the program / operation in Auto mode. This button will operate
only in Auto mode.
Reset:
Reset any program / MDI activity being carried out on the machine. Pressing this button
will also stop the homing activity being carried out on the machine.
Lubrication ON:
Pressing this button will initiate automatic lubrication. Lubrication system will be activated
for 4 seconds once this button is pressed.
Page 26 of 234
4.0 Switching ON and Switching OFF the machine:
4.1 Switching ON the machine:
1 Switch ON the main power supply

Switch ON the power supply to which electrical power supply of the control
panel is connected.
2 Switch ON the Machine ON / OFF Switch
Switch ON the Machine ON switch on the MOP
3 Switch ON the CPU in the operation pendant
Switch ON the CPU which is placed in the Operational pendant.
4 Start CutViewer Software
Once boot is completed, start CutViewer software (CutViewer TURN for CNC
Lathe Trainer and CutViewer Mill for CNC Mill Trainer).
5 Release Emergency Switch
Release Emergency Switch
6 Press ‘Machine on’ Soft button to start the machine
Press ‘Machine ON’ button on the MOP which is placed below Emergency
Swicth
4.2 Switching OFF the machine:
1 Take all axes to home position

Go to reference mode and take all axes to home position by pressing X+ (To
home X Axis), Y+ (To home Y Axsi) and Z+ (To home Z Axis).
2 Press Emergency Switch
Press Emergency Switch
3 Press ‘Machine On’ soft button to switch Off the machine
Switch OFF the machine by pressing ‘Machine ON’ soft button.
4 Close the CutViewer software
Close CutViewer Software
5 Switch OFF the Machine ON / OFF switch
Switch OFF Machine ON / OFF switch
6 Switch OFF the main power supply
Switch OFF the power supply to which electrical power supply of the
control panel is connected.
Page 27 of 234
5.0 JOG Mode:
JOG mode is activated by pressing the JOG key on the MOP. As soon as the JOG mode is
activated LED of JOG key on MOP is lit.
In the JOG mode, you can see the screen as shown below:
Page 28 of 234
5.1 JOG Menu Functions
Turret
Coordinate Position Current Tool Position Home
Activate
Work Offset
X to M/C Zero
Y to M/C Zero
Lubrication Tab
Stop M/C Zero
Axis JOG Tool Position
Tool
Configuration
Pulses
Tool Offset
Spindle Tab
Coolant Tab
Alarm Log
Spindle RPM
Active Alarms
Feed Rate Work Offset
M/C Usage
Page 29 of 234
Coordinate Position:
This window displays the current position of X and Z axes.
Axis JOG:
This window provides facility to jog all axes through software. Function of the X+ / Y+ / Z+ /
X- / Y- / Z- buttons are exactly similar to the functions of JOG buttons on MOP.
Pulses:
Pulses indicate the number of pulses given to each axis when corresponding JOG button is
pressed. For example, if 100 pulses are selected and user presses X+ button in software or on
MOP, 100 pulses will be given to stepper / servo motor of X Axis in positive direction. User can
select the number of pulses by clicking on the dropdown arrow.
Spindle Tab:
Page 30 of 234
Spindle can be operated through this tab. Functionally, it is similar to ‘Spindle CW’, ‘Spindle
CCW’ and ‘Spindle Stop’ buttons on the MOP
Spindle Speed RPM:
User can scroll in this tab to increase or decrease the spindle speed. The change in spindle
speed is dynamic.
Feed Rate:
User can scroll in this tab to change feed rate of axes movements in JOG mode. The change in
Feed rate is dynamic.
Current Tool Position:
Tool Position in this tab indicates the current tool position of the Turret. User can change the
tool by changing the tool position clicking on the dropdown arrow.
Once user selects the desired tool, following tab will be displayed on the software screen.
Page 31 of 234
User can select to use offset or change the tool without compensating for tool offset. Ideally,
user should always select the tool by activating ‘Use Offset’ option to avoid any accidents.
Turret Home:
User can press ‘Turret Home’ button to move turret to Home position. User has to be careful
before selecting this option to avoid collision during Tool Change. ‘Turret Home’ position is
nothing but Tool position no. 1. In other words, when user presses ‘Turret Home’ button, he is
selecting tool position number 1. Turret should always be in Home position before executing
any automatic program on the machine.
Lubrication Tab:
User can switch on the lubrication through this tab.
Page 32 of 234
Time tab indicates the time in seconds for which lubrication will be ON. Ideally, lubrication
duration should be 4 seconds.
Coolant Tab:
This tab is functionally similar to Coolant soft key on the MOP.
Work Offset:
This option will activate Work Offset.
M/C Zero X:
This option is used to move X Axis to M/C Zero position. This function is available only in
machines equipped with servo motors (Models: SLT 100 Servo / SLT 150 Servo)
M/C Zero Z:
This option is used to move Z Axis to M/C Zero position. This function is available only in
Stop M/C Zero:
Page 33 of 234
This option will stop the M/C Zero operation instantaneously. This function is available only in
Tool Position:
During the initial startup of the machine, user has to define a tool position. This procedure is
explained in details in later part of the operating manual.
Once user clicks on the Tool position tab, following window opens.
User can enter the current tool position in this window.
Tool Config:
Page 34 of 234
User can define the tool configuration through this option. During the installation and
commissioning of the machine, all of the tools in the turret are properly defined. User has to
change the definition if any of the tools is changed or if its position is modified.
Once user clicks on ‘Tool Config’ tab, following option opens:
Page 35 of 234
Process to configure a tool:
Step 1: Select the tool number (From the turret) in the left side table which is to be
configured.
Step 2: Select the type of tool from the right side table
Step 3: Click on ‘Assign’. Following window will open
Step 4: Enter the X Offset and Z Offset. If user has defined the tool as a drilling tool, she has to
enter diameter of the drilling tool.
Tool Offset:
This option is provided to define tool offsets. Clicking on ‘Tool Offset’ tab will open following
window:
Page 36 of 234
As seen in the above image, user can define X offset as well as Z Offset of any tool through
this window. Ideally, user should not change the tool change position as well as intermediate
position (before tool change) from the preset values.
Alarm Log:
This option will open the alarm log.
Active Alarms:
This option will open currently active alarms.
Page 37 of 234
Work Offset:
‘Work Offset’ tab will open the Work Offset window.
Page 38 of 234
M/C Usage:
‘M/C Usage’ will open the details of machine usage.
Page 39 of 234
6.0 AUTO Mode:
Auto mode is used to operate any program on CNC machine. Most of the MOP keys which are
related with the execution of CAM programs such as ‘Cycle Start’, ‘Cycle Stop’ will operate
only in Auto Mode.
Once user clicks on the ‘Auto’ button on the MOP, he will see following screen. LED on the
Auto key of MOP will be lit to indicate that Auto mode has been activated.
To execute any program (In simulation mode or in machining mode), user has to switch to
AUTO mode first. How to switch between different operating modes (JOG / AUTO /
REFERENCE) is explained in detail in the later part.
In AUTO mode, user can write an NC program or load previously saved program and execute
the same in machining or simulation mode.
Once, AUTO mode is activated, user will see following screen.
Page 40 of 234
In Auto mode, there are different modes in which program can be executed. These different
modes are as follows:
1. Simulation Mode
2. Machining Mode
3. Dry Run Mode
4. FMS Mode
These modes can be selected from the ‘Mode’ option in the Main Tabs.
Selection of Different
Machine Modes
Page 41 of 234
6.1 Simulation Mode
Simulation mode is generally used for checking the program that user wants to execute on
the machine. In simulation mode, there is no movement of the machine. User can see the
simulation of the program on the screen. In simulation mode, MOP keys are not active. That
means to start the simulation of program in ‘Simulation Mode’ user should press the start key
from the software and not from the MOP.
6.1.1 How to simulate a program in simulation mode:
Step 1: Activate AUTO Mode from MOP
Step 2: Go to Mode Tab in the List of Main tabs at the top of your screen and click on
Simulation Mode.
Step 3: Load the previously saved program from File  Open or write the program that user
wants to simulate.
Page 42 of 234
Step 4: Click on the ‘Run’ button on the top of your screen. In case if user wants to simulate
the program step by step, he can click on the ‘Step Forward’ button next to ‘Run’ button in
menu screen.
User has to keep in mind that when machine is in Simulation mode; ‘Cycle Start’ / ‘Cycle Stop’
and ‘Reset’ buttons from MOP are deactivated.
‘Run’ to simulate the Step Forward for Single

program step Simulation
Page 43 of 234
During the simulation of the program, user can pause the simulation at any time by pressing
the ‘Pause’ button. The simulation can be restarted from the paused position by pressing the
start button again.
Zoom / Measure functions will be operational in Simulation mode as well.
Page 44 of 234
6.2 MACHINING Mode

Machining mode is dedicated for the machining operation on the machine. If the user runs the
program in machining mode, he should expect the machine movement along with spindle
operation in accordance with the commanded program.
In machining mode, dynamic simulation of the current process which is being executed on the
machine will be simulated on the software screen in 2 as well as 3 dimensions.
Consider following example;
G01 Z100 F100
G01 Z0 F100
In this example, tool will reach immediately to Z100 in the software simulation whereas it will
take some time for the tool to actually reach the Z 100 position in the machine. As soon as
tool physically reaches the Z 100 position, next step will be immediately executed in the
software simulation. User has to understand that program is simulated on ‘Line by Line’ basis.
The position of the actual tool in the machine is not exactly the same as that of the position
of the tool in software.
In Machining Mode, both MOP as well as software controls are activated. That means, user can
start the program by pressing ‘RUN’ button from the software screen or ‘Cycle Start’ button on
the MOP.
User has to be very careful in machining mode especially about the tool position and work
offset. Kindly refer the tool offset and work offset procedures carefully before operation the
machine in machining mode.
It is always better (For educational purpose machines) for user to newly enter the tool
position before starting any program in machining mode even though the size of the
workpiece has not changed.
Page 45 of 234
6.2.1 How to simulate a program in Machining Mode:
Step 1: Activate AUTO Mode from MOP
Step 2: Go to Mode Tab in the List of Main tabs at the top of your screen and click on
Machining Mode.
Step 3: Go to ‘JOG’ mode and update the tool position precisely. Please refer tool offset / work
offset procedures carefully.
Step 4: Go to ‘AUTO’ mode.
Step 5: Press ‘Cycle Start’ button on MOP or press Run button from the software.
6.3 Switching between ‘JOG’ mode and ‘AUTO’ mode:
Once the referencing of the machine is done, user has to operate machine in either ‘JOG’
mode or in ‘AUTO’ mode. Hence, it is important to know how to switch between these modes.
In ‘AUTO’ mode, there are different machine modes such as ‘Simulation Mode’, ‘Machining
Mode’, ‘Dry Run Mode’ and ‘FMS Mode’.
Page 46 of 234
When switching from ‘AUTO’ mode to ‘JOG’ mode, machine mode should always be
‘Machining Mode’. If user presses ‘JOG’ button while in ‘Simulation Mode’, ‘JOG’ mode will not
be activated.
User first has to select ‘Machining Mode’ before pressing the JOG button to activate ‘JOG’
mode.
While switching from JOG mode to AUTO mode; user has to press AUTO button from MOP.
Page 47 of 234
7.0 CNC Coordinate System
As a rule, a coordinate system is formed from three mutually perpendicular coordinate axes.
The positive directions of the coordinate axes are defined using the so-called "3-finger rule" of
the right hand. The coordinate system is related to the workpiece and programming takes
place independently of whether the tool or the workpiece is being traversed. When
programming, it is always assumed that the tool traverses relative to the coordinate system of
the workpiece, which is intended to be stationary.
The figure below illustrates how to determine the axis directions.
7.1 Machine coordinate system (MCS):
The orientation of the coordinate system relative to the machine depends on the machine
type. It can be rotated in different positions.
The directions of the axes follow the "3-finger rule" of the right hand. Seen from the front of
the machine, the middle finger of the right hand points in the opposite direction to the in feed
of the spindle.
The figure below shows an example of the machine coordinate system of a turning machine.
Page 48 of 234
The origin of this coordinate system is the machine zero.

This point is only a reference point which is defined by the machine manufacturer. It does not
have to be approachable.
The traversing range of the machine axes can be in the negative range.
7.2 Workpiece coordinate system (WCS)

To describe the geometry of a workpiece in the workpiece program, a right-handed, right-
angled coordinate system is also used.
The workpiece zero can be freely selected by the programmer in the Z axis. In the X axis, it lies
in the turning center.
The figure below shows an example of the workpiece coordinate system.
Page 49 of 234
7.3 Clamping the workpiece
For machining, the workpiece is clamped on the machine. The workpiece must be aligned such
that the axes of the workpiece coordinate system run in parallel with those of the machine.
Any resulting offset of the machine zero with reference to the workpiece zero is determined
along the Z axis and entered in a data area intended for the settable work offset. In the NC
program, this offset is activated during program execution, for example, using a programmed
G54
command.
The figure below shows an example of the workpiece clamped on the machine.
Page 50 of 234
7.4 Taking Tool Offset:
The geometries of the machining tool must be taken into consideration when user executes a
part program. These are stored as tool offset data in the tool list. Each time the tool is called,
the control considers the tool offset data.
You can determine the tool offset data, including the length, radius and diameter by either
measuring the tool or entering the values in the tool list.
As per the actual position of the point F (the machine coordinate) and the reference point, the
control system can calculate the offset value assigned to the lengths for the X and Z axes.
See the following illustration for determining the length offsets using the example of a turning
tool:
See the following illustration for determining the length offsets using the example of a drill:
Length 1/Z axis
Page 51 of 234
7.4.1 Tool Offset:
User needs to understand that tool offset is a single time process which need not be
performed until any of the tool is replaced / modified. In case if a tool is damaged, user can
modify the offsets of that particular tool only (Provided Tool No. 1 intact) without changing
the offsets of all other tools.
Step 1:
The most important part in taking accurate tool offsets is to define each and every tool
accurately. Any of the manual activity such as defining tool offset / tool position / work offset
is done through JOG menu.
Go to JOG by pressing ‘JOG’ on the MOP
Following Window will open:
Step 2:
Now, user has to define each tool carefully. User has to note that for a flat bed machine, Right
hand turning tool is used whereas for slant bed machine, left hand turning tool is used. This
basic difference is due to the position of the turret in each machine.
Click on ‘Tool Config’ Tab
Following window will open:
Page 52 of 234
Step 3:
From the left tab, select a tool that you want to define. From the right tab, select the
appropriate type of the tool. Once appropriate tool type is selected, click on ‘Assign’.
Following window will open:
Page 53 of 234
Step 4:
Initially, keep X Offset and Z Offset as 0 for all tools. For drilling tools, define the drill diameter.
User will not be able to enter any diameter value if he defines the tool other than a drilling
tool.
Define the Diameter of the tool in case of drilling tools and Click ‘OK’.
Step 5:
Go to JOG and click on the ‘Home’ button in Tools Menu.
Click on Turret ‘Home’
Turret home represents the position of turret when tool number 1 is activated. In other words,
user can home the turret by selecting Tool number 1 from the tool dropdown list in Tool tab.
Make sure that current tool indicated in the JOG and the tool which is currently active in the
tool turret is Tool Number 1.
Page 54 of 234
Step 6:
Go to Tool Position by clicking on ‘Tool Pos’ button.
Following window will open.
Step 7:
User is expected to take tool to any fixed position.
For example, user can touch the tool on the surface of the workpiece in X axis. At the same
time, tool should be at the edge of the workpiece.
Tool No.1 Touching the outer surface of the Job Tool No.1 Touching the face of the Job
Page 55 of 234
Assuming that diameter of the cylindrical job is 25, current position of the tool is 25mm in X
axis and 0mm in Z axis.
Enter Current position of the tool in Tool position Tab and click OK
Step 8:
Click on the ‘Tool Offset’ button in the JOG panel.
Step 8:
Click on ‘Set Current Pos as Ref’ button. Then Click on the ‘X Offset’ and ‘Z Offset’ buttons.
This will set the current position of the tool as a reference position.
Step 9:
Page 56 of 234
In the same window, select tool number 2 from tool dropdown menu.
Select Tool No. 2
Once user selects desired tool number, tool will be automatically changed in the turret.
Step 10:
In the same window, select tool number 2 from tool dropdown menu.
Assuming that tool number 2 is a drilling tool with 8 mm diameter and the same has been
defined correctly in the tool list, we will proceed to take offset of tool no. 2.
Step 11:
Move the tool in such a way that outer surface of the drilling tool makes slight contact with
the cylindrical workpiece. At this position, click on X offset.
Page 57 of 234
When outer surface of drilling tool is slightly touching

the surface of cylindrical workpiece, click on ‘X Offset’
Step 12:
Move the tool in such a way that drill tip touches the face of the cylindrical workpiece. At this
position, click on the ‘Z Offset’ button..
When tip of drilling tool is slightly touching the face

of cylindrical workpiece, click on ‘Z Offset’
Step 13:
Repeat the procedure from Step 9 to Step 12 for all tools.
Page 58 of 234
7.4.2 Taking Work Offset:
The machine coordinate system does not change, however we want to be able to do the
Turning operation of our part anywhere we want on the machine. We will normally use the
“work” coordinate system, which we can shift anywhere we want.
Suppose our g-code file containing the work piece is created with an origin of X=0, Z=0. This is
because you have drawn your part in a CAD program beginning from these coordinates and
then converted to G-Code.
Now you have put your raw material somewhere on the machine, probably not at coordinates
X=0, Z=0. Ideally, Face plane of the cylindrical job as Z=0, such that a negative Z value goes
into the material.
User has to understand that position and size of the each job loaded in the chuck can be
different. Hence it is always suggested to take work offsets before executing an new part
program.
Step 1:
Go to JOG and click on the ‘Home’ button in Tools Menu.
Click on Turret ‘Home’
Turret home represents the position of turret when tool number 1 is activated. In other words,
user can home the turret by selecting Tool number 1 from the tool dropdown list in Tool tab.
Page 59 of 234
Make sure that current tool indicated in the JOG and the tool which is currently active in the
tool turret is Tool Number 1.
Step 2:
Go to Tool Position by clicking on ‘Tool Pos’ button.
Step 3:
User is expected to take tool to any fixed position.
For example, user can touch the tool on the surface of the workpiece in X axis. At the same
time, tool should be at the edge of the workpiece.
Tool No.1 Touching the outer surface of the Job Tool No.1 Touching the face of the Job
Page 60 of 234
Assuming that diameter of the cylindrical job is 25, current position of the tool is 25mm in X
axis and 0mm in Z axis.
Enter Current position of the tool in Tool position Tab and click OK
Page 61 of 234
7.5 Coordinate Geometry
The major step towards the basic understanding of CNC principles and geometrical concepts
is the understandings of a subject known in mathematics as the system of coordinates.
System of the co-ordinates is founded on a number of mathematical principles dating back
over four hundred years. The most important of these principles are those that can be applied
to the CNC technology of today. In various publications on mathematics and geometry, these
principles are listed under the headings like the real number system and the rectangular
coordinates.
7.5.1 REAL NUMBER SYSTEM
The key to understanding the rectangular coordinates is the knowledge of arithmetic, algebra
and geometry. The key knowledge in this area is the knowledge of real number system. Within
the real number system, there are ten available numerals (digits), 0to 9 (zero to nine), that can
be used in any of the following groups:
 Zero integer… 0
 Positive integers... 1,2, +3,10,12943, +45
(with or without sign)
 Negative integers -4, -381, -25, -77
(Minus sign required)
 Fractions… 1/8, 3/16, 9/32, 35/64
 Decimal fractions… 0.185, .2, .546875, 3.5
All groups are used almost daily. These groups represent the mainstream of just about all the
applications of number s in modern life. In CNC programming, the primary goal is to use the
numbers to ‘translate’ the drawing, based on its dimensions, into a cutter path.
Computerized Numerical Control means control by the numbers using a computer. All
information in a drawing has to be translated into a CNC program, using primarily numbers.
Numbers are also used to describe commands, functions, comments, and so on. The
mathematical concept of a real number system can be expressed graphically on a straight line,
called the Number scale, where all divisions have the same length
The length of each division on the scale represents the unit of measurement in a convenient
and generally accepted scale. It may come as a surprise that this concept is used every day.
For example, a simple ruler used in schools is based on the number scale concepts, regardless
of measuring units. Weight scales using tons, pounds, kilograms, grams and similar units of
Page 62 of 234
mass are other examples. A simple household thermometer uses the same principle. Other
similar examples are available as well.
7.5.2 RECTANGULAR COORDINATE SYSTEM
Rectangular coordinate system is a concept used to define a planar 2D point, using the XY
coordinates. It was first defined in the 17th century by a French philosopher and mathematician
Rene Descartes (1596-1650). His name is used as an alternative to the rectangular coordinate
system, called the Cartesian coordinate system.
The concepts used in design, drafting and in numerical control are over 400 years old. A given
point can be mathematically defined on a plane (two coordinate values) or in space (three
coordinate values). The definition of one point is relative to another point as a distance
parallel with one of the three axes that are perpendicular to each other. In a plane, only two
axes are required, in the space, all three axes must be specified. In programming, point
represents an exact location. If such location is on plane, the point is defined as 2D point,
along two axes. If the location is in a space, the point is defined as a 3D point, along three
axes.
When two number scales that intersect at right angles are used, mathematical basis for
Rectangular Coordinate System is created. Several terms emerge from this presentation, and
all have an important role in CNC programming. Their understanding is very important for
further progress
7.5.3 Axes and Planes
Each major line of the number scale is called an axis. This old principle, when applied to CNC
programming, means that at least two axes- two number scales- will be used. This is the
mathematical definition of axis:
An axis is a straight line passing through the centre of a plane or a solid figure,
around which the parts are symmetrically arranged.
The definition can be enhanced by a statement that an axis can be a line of reference. In CNC
programming, an axis is used as a reference all the time. The definition contains the word
‘plane’. A plane is term used in 2D applications, while a solid object is used in 3D applications.
Mathematical definition of plane is:
A plane is a surface in which a straight line joining any two of its points will lie
wholly in the surface.
Page 63 of 234
From the top viewpoint of the observer, looking straight down on the illustration figure a
viewing direction is established. This I soften called viewing a plane
A plane is a 2d entity- the letter X identifies its horizontal axis the letter Y identifies its vertical
axis. This plane is called the XY plane. Defined mathematically, the horizontal axis is always
listed as the first letter of the pair. In drafting and CNC programming, this plane is also known
as top view or a Plan view. Other planes are also used in CNC programming, but not to the
same extent as in CAD/ CAM work.
Point of Origin
Another term that emerged from Rectangular coordinate system is called the point of origin,
or just origin. It is the point where the two perpendicular axes intersect. This point has a zero
coordinate value in each axis, specified as planar X0Y0 and special X0Y0Z0- figure
This intersection has a special meaning in CNC programming. The origin acquires a new name,
typically the program reference point. Other terms are also used: program zero part reference
point, work piece zero, part zero with the same meaning and purpose.
Quadrants
Viewing the two intersecting axes and the new plane, four distinct areas can be clearly
identified. Each area is bounded by two axes. These areas are called quadrants.
Mathematically defined,
A quadrant is any one of the four parts of the plane formed by the system of rectangular
coordinates.
The word quadrant (from Latin word quadrans or quadrantis, meaning the four part), suggests
fur uniquely defined areas or quadrants. Looking down in the top
Page 64 of 234
View at the two intersecting axes, the following definitions apply to quadrants. They are
mathematically correct and are used in CNC/CAD/CAM applications:
The quadrants are defined in the counterclockwise direction from the horizontal X axis and
the naming convention uses Roman numbers, not Arabic numbers normally used.
The counting starts at the positive side of the horizontal axis. Figure illustrates the definitions.
Any point coordinate value can be positive, negative or zero any coordinate value is
determined solely by the location of the defined point in particular quadrant and its distance
along an axis, relative to the origin- figure
• IMPORTANT
If he defined point lies exactly on the X axis, it has the Y value equal to zero (Y0)
If the point lies exactly on the Y axis, it has the X value equal to zero (X0)
If the point lies exactly on both X and Y axes, both X and Y values are zero (X0 Y0).
X0Y0Z0 is the point of origin. In part programming, positive values are written without the
plus sign figure
 Right Hand Coordinate System

In the illustration of the scale, quadrants and axes, the origin divides each axis into two
portions. The zero point – the point of origin-separates the positive sections of the axis from
the negative section. In the right hand coordinate system, the positive axis begins at the origin
and is directed towards the right for the X axis, upwards for the y axis and towards the
perpendicular viewpoint for the Z axis. Opposite directions are negative.
Page 65 of 234
If these directions were superimposed over a human right hand, they would correspond to the
direction from the root of thumb or finger towards its tip. The thumb would point in the X
direction, the index finger in the Y direction and the middle finger is the Z direction.
The majority of CNC machines are programmed using the so called absolute coordinate
method that is based on the point of origin X0Y0Z0. This absolute method of programming
follows very strictly the rules of rectangular coordinate geometry and all concepts covered in
this chapter.
7.5.4 MACHINE GEOMETRY
Machine geometry is the relationship of distances between the fixed point of the machine
and the selectable point of the part. Typical geometry of the CNC machine uses the right hand
coordinate system. The positive and negative axis direction is determined by an established
viewing convention. The basic rule for the Z axis is that it is always the axis along which a
simple hole can be machined with a single point tool, such as drill, reamer, wire or a laser
beam. The figure 4.8 illustrates the standard orientation of XYZ type machine tools
 Axis Orientation - Turning
Most CNC the X axis is the table longitudinal direction, the y axis is the saddle cross direction
and the Z axis is the spindle direction lathe have two axes, X and Z. More axes are available
but they are not important at this point. A special third axis the, C axis is designed for milling
operation(live tooling) and is an option to the typical CNC lathe.
What is more common for CNC lathe in industry is the double orientation of the XZ axes.
Lathes are distinguished as front and rear lathes. An example of front lathe is similar to
conventional engine lathe. All the slant bed types of lathe are of rear kind. Identification of the
axes has often not followed mathematical principles.
Another variety, a vertical CNC lathe, is basically a horizontal lathe rotated 900. Typical axes for
the horizontal and vertical machine axes, as applied to turning, are illustrated in figure
 Additional Axes
Page 66 of 234
A CNC machine of any type can be designed with one or more additional axes, normally
designed as secondary axes using the U, V, W letters. These axes are normally parallel to the
primary X, Y and Z axes respectively.
For a rotary or an indexing application, the additional axes are defined as A, B and C axes, as
being the rotated about the X, Y, Z axes, again in their respective order. Positive direction of a
rotary (or an indexing) axis is the direction required to advance a right handed screw in the
positive X, Y, Z axes. The relationship of the primary and the secondary (or supplementary)
axes shown in figure Arc center modifiers (sometime called the arc center vectors) are not
true axes, yet they are also related to primary axes XYZ.
Page 67 of 234
8.0 CNC Programming:
A CNC program is composed of a series of sequential instructions related to the machining of

a part. Each instruction is specified in a format the CNC system can accept, interpret and
process. Each instruction must also conform to the machine tool specifications.
This input method of a program can be defined as an arrangement of the machining and
related instructions, written in the format of CNC system and aimed at a particular machine
tool.
Various controls have a different format, but most are similar. Subtle differences exist among
CNC machines from different manufacturers, even those equipped with the same control
system. This is common, considering the specific demands individual machine builders place
upon the control manufacturer to accommodate many original and unique machine design
features. Such variations are usually minor but still important for programming.
8.1 BASIC PROGRAMMING TERMS
The field of CNC has its own terminology and special terms and its jargon. It has its own
abbreviation and expression that only people in the field can understand. CNC programming ii
sonly a small section of the computerized machining and it has a number of its own
expressions. The majority of them relate to the structure of program.
There are four basic terms used in CNC programming. They appear in the professional articles,
books , papers, lectures and so on. These words are the key to understanding the general CNC
terminology:
Character Word Block Program
Each term is very common and important in CNC programming and deserves its own detailed
explanation.
Character
A character is the smallest unit of CNC program. It can have one of three forms:
1. Digit
2. Letter
3. Symbol
Characters are combined into meaningful words. This combination of digits, letters, and
symbols is called the alpha-numerical program input.
Page 68 of 234
Digits
There are ten digits, 0to 9, available for use in a program to create numbers. The digits are
used in two modes- one for integer values (numbers without a decimal point), the other for
real numbers (numbers with a decimal point). Numbers can have positive or negative values.
On some controls real numbers can be used with or without the decimal point. Numbers
applied in either mode can only be entered within the range that is allowed by the control
system.
Letters
The 26 letters of the English alphabet are all available for programming, at least in theory.
Most control system will accept only certain letters and reject others. For example, a CNC
lathe control will reject the letter Y, as the Y axis is unique to milling operations ( milling
machines and machining centers). Capital letters are normal designation in CNC programming,
but some controls accept low case letters with the same meaning as their upper case
equivalent.
If in doubt, use CAPITAL letters only!

Symbols
Several symbols are used for programming, in addition to the digits and letters. The most
common symbols are the decimal point, minus sign, percent sign, parenthesis and others,
depending on the control options.
Word
A program word is a combination of alpha-numerical characters, creating a single instruction
to the control system. Normally, each word begins with a capital letter that is followed by a
number representing a program code or the actual value. Typical words indicate the axes
position, federate, speed, preparatory commands, miscellaneous functions and many other
definitions.
Block
Just like the word is used as a single instruction to the CNC system, the block is used as a
multiple instruction. A program entered into the control system consists of individual line of
instructions, sequenced in a logical order. Each line is called a sequence block or simply a
block – is composed of one oe several words and each word is composed of two or more
characters.
In the control system, each box must be separated from all the others. To separate blocks in
MDI (Manual Data Input) mode at the control, each block has to end with a special End of
Block code (symbol). This code is marked as EOB on the control panel. When preparing the
program on a computer, the Enter key on the keyboard will terminate the block with the same
Page 69 of 234
result (similar to the old carriage return on typewriters) when writing a program on paper first,
each program block should occupy only a single line on the paper. Each program block
contains a series of single instructions that are executed together.
Program
The part program structure varies for different controls, but the logical approach does not
change from one control to another. A CNC program usually begins with a program number or
similar identifications, followed by blocks of instructions in a logical order. The program ends
with a stop code or a program termination program symbol, such as the Percent sign-%.
Internal documentation and message to the operator may be placed in strategic places within
the program. The programming format has evolved significantly during the years and several
formats have emerged.
8.2 PROGRAMING FORMATS
Since the early days of numerical control three formats had become significant in their time.
They are listed in a order of their original introduction:
 Tab Sequential Format NC only – no decimal point
 Fixed Format NC only – no decimal point
 Word Address Format NC or CNC – decimal point
Only the very early control systems use the tab sequential or fixed formats. Both of them
disappeared in the early 1970’s and are now obsolete. They have been replaced by the much
more convenient Word Address format.
8.3 WORD ADDRESS FORMAT
The word address format is based on a combination of one letter and one more digits – figure
In some applications such a combinations can be supplemented by a symbol, such as a minus
sign or decimal point. Each letter, digit or symbol represents one character in the program and
in the control memory. This unique alpha- numerical arrangement creates a word, where the
letter is the address, followed by numerical data with or without symbols. The word address
refers to a specific register of the control memory. Some typical words are :
G01 M30 D25 X5.75 N105 H01 Y0 S2500
Z-5.14 F12.0 T0505 T05 /M01 B180.0
Page 70 of 234
CHARACTERS
6 F
WORDS
F 2 7 5 . 0 G 0 1 N 5
BLOCKS
N 5 G 0 1 Y - 6 4 6 F 2 7 5
The address the letter in the block defines the meaning of the word and must always be
written first. For example X5.75 is correct, 5.75X is not. No spaces (space characters) are
allowed within a word, but they are only allowed before the word, meaning before the letter.
Data indicates the word numerical assignment. This value varies greatly and depends on the
preceding address. It may represent a sequence number N, a preparatory command G, a
miscellaneous function M, an offset register number D or H, a coordinate word X, Y or z, the
federate function F, the spindle function S, the tool function T, etc.
Any one word is a series of characters (at least two) that define a single instruction to the
control unit and the machine. The above examples of typical words have the following
meaning in a CNC program:
G01 Preparatory Command
M30 Miscellaneous function
D25 Offset number selection – mills
X5.75 Coordinate word –positive value
N105 Sequence number (block number)
H01 Tool length offset number
Y0 Coordinate word- zero value
S2500 Spindle Speed function
Z-5.14 Coordinate word- negative value
F12.0 Feed rate function
T0505 Tool function- lathes
T05 Tool function- mills
Page 71 of 234
/M01 Miscellaneous function w/block skip symbol
B180.0 Indexing table function
Individual words are instructions grouped together to form sequences of programming code.
Each sequence that will process a series of instruction simultaneously forms a unit called a
sequence block or simply a block. The series of blocks arranged in a logical order that is
required to machine a complete part or a complete operation is the part program also known
as a CNC program.
The next block shows a rapid tool motion to the absolute position of X13.0 Y4.6, with a coolant
turned on:
N25 G90 G00 X13. 0 Y4.6 M08
Where:
N25 Sequence or block number
G90 Absolute mode
G00 Rapid motion mode
X13.0 Y4.6 Coordinate location
M08 Coordinate ON function
The control will process any one block as a complete unit – never partially. Most control
allows a random word order in a block, as long as the block number is specified first.
8.4 FORMAT NOTATION
Each word can only be written in a specific way. The number of digits allowed in a word,
depending on the address and maximum number of decimal places, is set by the control
manufacturer. Not all letters can be used. Only letter with an assigned meaning can be
programmed, except in a comment. Symbols can be used in only some words, and their
position in the word is fixed. Some symbols are used only in custom macros. Control
limitations are important. Symbols supplement the digits and letters and provide them with an
additional meaning. Typical programming symbols are the minus sign, decimal point, percent
sign and a few others. Al symbols are listed in a table below.
Page 72 of 234
Short Forms:
Control manufacturers often specify the input format in an abbreviation form.
X + 5.3
X: - Described Address
+:- Positive or Negative Value Number
5:- Number of Digit before Decimal Point
. : - Decimal Point
3:- Number of Digit after Decimal Points
The full format description for each meaning would be unnecessarily too long. Consider the
following complete and not abbreviated description of the address X-as a coordinate word
that is used in the metric system;:
Address X accepts positive or negative data with the maximum of five digits in front of a
decimal point and three digits maximum behind the decimal point-decimal point is allowed.
The absence of a decimal point in the notation means is not used; the absence of plus (+) sign
in the notation means that the address value can not be negative- a lack of sign means a
positive value by implication. These samples of format notation explain the shorthand:
G2 Two digits maximum, no decimal point or sign
N5 five digits maximum, no decimal point or sign
F5 Five digits maximum, no decimal point or sign
F3.2 Five digits maximum, three digits maximum in front of the decimal point, two
digits maximum behind the decimal point, decimal point is allowed, no sign is
used.
Be careful when evaluating the shorthand notations from a manual. There are no industry
standards and not all control manufacturers use the same methods, so the meaning of the
short forms may vary significantly. The list of addresses, their format notation and description
is listed in the following tables. They contain address notations based on atypical Fanuc
Control system.
Page 73 of 234
8.5 PROGRAMMING TIPS
Programming is just like any other work- with good knowledge and appositive attitude; it can
be done right and with first class results. Here are some tips to get the best result from any
programming effort.
 Approach CNC programming in a logical and methodological way.
 Always calculate unknown values – never guess.
 Check the actual size of the blank material – do not count on the paper
dimensions.
 Standardize a programming style and adhere to it.
 Program dimensional values in absolute mode whenever possible.
 Make a setup sheet and/or tooling sheet before programming, not after.
 Program as many machining operations in a single setup as possible.
 Use minimum numbers of tools for maximum number of jobs- standardize.
 Always program for the safety of CNC machining.
 Document your work and store everything relating to the program

development.
 Use cutter radius compensation for contouring, if possible.
 Use any suitable built in cycles the CNC system offer.
 Watch for programming errors- syntax and logical- all errors are avoidable.
 Use a microcomputer and text editor to write and print the program hard copy.
 Apply the use of subprograms to prevent errors caused by repetition.
 Make sketches for calculation simple, clear and always in scale.
 Place comments to the CNC operator in the program printed copy.
 Do not forget ‘small’ items – such as coolant and spindle stop.
 The CNC operator can be an excellent resource of valuable information –

communicate.
 Avoid programming excessive clearances or dwells.
 Keep the program under your control – not the operators.
 Admit an error if you made one – do not blame other people unfairly.
 Always write the program for the convenience of the CNC operator – not yours.
Page 74 of 234
 Check, double check and triple check the program
 Write as much of the program in one sitting as possible.
8.6 Absolute/incremental dimensioning: G90, G91
Functionality:
With the instructions G90/G91, the written positional data X, Z are evaluated as a coordinate
point (G90) or as an axis position to traverse to (G91). G90/91 applies for all axes.
These instructions do not determine the path by which the end points are reached; this is
provided by a G group (G0, G1, G2 and G3...).
Programming
G90 ; Absolute dimension data
G91 ; Incremental dimension data
See the following different dimensioning types in the drawing:
Absolute dimensioning G90
With absolute dimensioning, the dimensioning data refers to the zero of the coordinate
system currently active (workpiece or current workpiece coordinate system or machine
coordinate system). This is dependent on which offsets are currently active: programmable,
settable, or no offsets.
Upon program start, G90 is active for all axes and remains active until it is deselected in a
subsequent block by G91 (incremental dimensioning data) (modally active).
Incremental dimensioning G91
With incremental dimensioning, the numerical value of the path information corresponds to
the axis path to be traversed. The leading sign indicates the traversing direction.
G91 applies to all axes and can be deselected in a subsequent block by G90 (absolute
dimensioning).
Page 75 of 234
9.0 MECHANICAL SYSTEM
The mechanical machine has the following parts:
1. Bed
2. Saddle, table and vertical slide
3. Spindle head
4. Tool rack
5. Axes drive system
6. Spindle drive system
9.1 Bed
Bed is built with high quality cast iron. The bed is fixed on to the base plate which is also used
as a chip tray. FG32 grade castings are used in Hytech CNC machines which provide stability
and rigidity.
9.2 Saddle, &Slide
The saddle and the slide have dovetail guide ways lined with Turcite to reduce friction. Option
of LM Guideways is also available in Servo motor based machines. The combination of Servo
motor drive, timing pulley & belt and ball screw-nut assembly ensures very accurate motion
and high resolution in both axes. The ball screws and guide ways are protected from chips and
dust by bellows.
9.3 Spindle Head
The spindle has ISO taper. The hardened and ground precision spindle runs on precision
antifriction ball bearings.
9.4 Axes Drive System
9.4.1 Stepper Motors
In CLT 100, NLT 90 and CLT 150 models, Permanent magnet DC Servo motors obtain all the
axes motions. Each linear step on the slides is 0.005mm. Details about Stepper motors and
servo motors re explained in section 13.0.
Page 76 of 234
9.4.2 Servo Motors
AC Servo Motors are used in SLT 100 and SLT 150 models for axes movements. Resolution of
servo motors is 0.001 mm. Details about Stepper motors and servo motors re explained in
section 13.0.
9.5 Spindle Drive System:
The spindle is driven by an AC motor. V Belt is used as a drive between spindle and AC spindle
motor. Spindle motor capacity in all of Hytech CNC Trainer machines is 2 HP. Maximum spindle
speed is 3,000 RPM. Speed variation in Spindle speed is carried out with the help of VFD
(Variable Frequency Drive). Speed variation from 300 RPM to 3000 RPM can be achieved with
the help of VFD.
9.6 BALL SCREW
Ball is a linear actuator. Primary function of ball screw in CNC Machine is to translate rotational
motion of a motor into linear motion of CNC machine axes. Ball screws are available in
numerous sizes. Generally, efficiency of a ball screw is 90 to 95% as compared to 35 to 40%
efficiency of a lead screw.
In Hytech CNC Lathe trainer machines, 25 x 5 ball screws are used for all axes. 25mm being the
diameter and 5 mm being the pitch. In other words, one complete revolution of ball screw will
translate into 5mm movement of the tool / axis.
9.6.1 Lubrication:
In view of the life and efficiency, precision ball screws require adequate lubrication, which
may be either greasing or oiling. For greasing, grease based on lithium soap is usually
recommended and for oiling. Turbine oil No.1 to No.3 (38 – 90CSt) is recommended.
Especially when heating from the ball screw under high speed, heavy-load conditions has an
effect on the accuracy, it is also necessary to take into account cooling by forced lubrication.
The nut of a ball screw usually runs on a long threaded shaft and the shaft rotates, which
makes it difficult to retain oil. Therefore, much care should be taken so that no oil shortage
takes place.
This is the reason that most of the CNC machines are equipped with automatic lubrication
systems. Especially in training and educational sector, instructors should take extra care in
providing necessary and timely lubrication to ball screws and guideways.
Page 77 of 234
9.6.2 Dirt Protection:
Dirt or foreign substances penetrating ball screws will grow into wear or damage, as with
roller bearings. In an environment which can involve dirt or foreign substances (such as chips).
Therefore, it is necessary to hermetically seal the threaded shaft with a dirt protection
(bellows, screw cover, etc). In an environment where no foreign substances exist but there is
dirt floating, the nut can be protected by a labyrinth seal, instead of a dirt protection .A small
clearance is provided between the labyrinth seal and the threaded shaft groove. This will limit
the dirt protection effect, although the mechanical efficiency is not degraded. A sealed ball
screw (...RR) can be used as it contains good No.2 grease based on lithium soap.
9.6.3 Radial Load and Moment Load
The nut structure should be such that the ball screw is not under a radial or moment load, any
radial or moment load will degrade the service life to a high degree and grow into a
malfunction.
9.6.4 Mounting
User should take extreme care that ball nut should never be separated from the ball screw.. If
this is unavoidable, use a sleeve which is approximately 1 mm smaller that the root diameter of
the threaded shaft and remove the balls together with the nut, without separating them. Also
take care that no balls fall off and that the ball tube is not damaged.
9.6.5 Precautions
Ball screws, which are high in accuracy, should not be handled roughly. Never attempt an
undue mounting on the housing.
Take care that the ball tube is not hit by anything. Do not keep a non-preloaded ball screw
vertical; otherwise the nut would drop by gravity.
Page 78 of 234
Servo Motors Vs Stepper Motors
‘HYTECH’ CNC Lathe machine is a two axis turning machine with an optional C Axis
arrangement. It is equipped with Hydraulic Chuck (optional) as well as Hydraulic Tailstock
(Optional). It comes with 8 station automatic turret. Maximum spindle speed it can achieve is
up to 6,000 RPM (Optional).
There are two different models of Hytech CNC machines, One with Servo motors as its feed
actuators and the other with Stepper Motors. Both of these machines are specially designed
for educational purpose. Various software and hardware limits prevent most of the accidents
that generally take place in production CNC Machines.
SLT 100 model is equipped with AC servo motors whereas CLT 100 model is equipped with
DC stepper motors.
Servo Motors Vs Stepper Motors:
It's true that any CNC machine with stepper motors is a lot cheaper than the CNC machine
with servo motor systems. But when it comes to something as critical as CNC Trainer
machine, quality cannot be compromised. Experienced machine tool users know that servo
motors are vastly superior to stepper motors, because newer, high-performance machines
(like CNC Mills / CNC Turns) use servo motors, whereas older, more troublesome machines
used stepper motors. Yet the real reason for the performance difference requires some
explanation.
Hytech Servo CNC machines use servo motors with optically-encoded feedback, so the
controlling software always knows the true position of the machine. A simple stepper motor
controller must "trust" that the motor has moved exactly as requested each time a step
current is made. Without feedback, the controller cannot identify and correct whenever the
motor misses a few steps (like during jolts, vibrations, hang-ups, etc.).
There is no control of CNC on the exact position of stepper motor. Communication between
CNC Controller and Stepper motor is single way. Hence, there is high risk of accidents
especially in educational industry in case of stepper motors.
Since a single shape may require millions of steps to trace, errors in position will continue to
accumulate without the recognition of the controller. Hence, errors in stepper position are
both unpredictable and unreported.
Page 79 of 234
In case of servo motors, communication between CNC controller and Servo motors is both
ways. Controller monitors the position of servo motor at every instance. Hence there is
significantly low risk of accidents in case of Servo motors.
Also, Servo motors used by Hytech (Mitsubishi / Siemens) have an internal power circuit
which does not need any stabilizer to be provided extra. These servo motors operate on AC
voltage of 415 volts (AC).
As you all know,

P (Power) = V (Voltage) x I (Current)
In both Stepper and Servo motors, P (Power) is the same.

In case of Servo motors, V (Voltage) is 415V (AC) where as in case of Stepper motors, V
(Voltage) is 60 V (DC).
Hence current required in case of Stepper motors is almost 7 times more than that required
in servo motors.
Heat Generated in a motor = I² (Current)² x R (Resistance) x T (Time)

Hence Heat generated in a servo motor is 49 times lesser than that generated in a stepper
motor.
Page 80 of 234
Temperature Vs Time Graph for Servo Motors & Stepper Motors:
Torque Vs RPM Graph for Servo Motors & Stepper Motors:
Page 81 of 234
Comparison of Servo Motor System and Stepper Motor System:
Characteristics Servo Motors Stepper Motors

Cost The cost for a servo motor system is Steppers are generally cheaper than servo
higher than that of a stepper motor motors that have the same power rating
system with equal power rating
High speed High Servo motors maintain their rated torque Stepper motors lose up to 80% of their
Torque to about 90% of their no load RPM maximum torque at 90% of their maximum
RPM
Resolution 1 micron 10 micron
Loop CLOSED LOOP – Error correction feedback OPEN LOOP – Encoder is not used
with encoder
Power to Servo motors have an excellent power to Stepper motors are less efficient than
Weight/Size Ratio weight ratio given their efficiency servo motors which usually mean a smaller
power to weight/size ratio.
Reserve Power It has 200 % to 300 % reserve power for No reserve power
Normal Load short duration at normal load
Efficiency Servo motors are very efficient yielding. Stepper motors consume a lot of power,
They yield 90% efficiency given light much of which is converted to heat.
loads Stepper motors are 60% to 70% efficient
Motor Motor stays cool. Current drawn is Motor draws full current at all the load
Temperature proportional to load. Hence, low condition
temperature
Flexibility in Since the encoder on a servo motor Stepper motors usually have 1.8 or 0.9
Motor Resolution determines the motor resolution servos degree resolution.
have a wide range of resolutions
Torque to Inertia Servo motors are very capable of Stepper motors may stall and skip steps if
Ratio accelerating loads. the motor is not powerful enough.
Reserve Power Since the current draw of a servo motor is Stepper motors draw excess current
and Torque proportional to the load applied, heat regardless of load. The excess power is
production is very low. dissipated as heat.
Least Heat A servo motor can supply about 200% of Stepper motors do not have reserve
Production the continuous power for short periods power.
Noise Servo motors produce very little noise. Stepper motors produce a slight hum due
to the control process.
Resonance and Servo motors do not vibrate or have Stepper motors vibrate slightly and have
Vibration resonance issues. some resonance issues because of the way
stepper motor operates.
Page 82 of 234
Siemens Servo Drive V-90
Page 83 of 234
Siemens Servo Drive (Model: V90)
Servo Motor
Page 84 of 234
System Connection Diagram:
Page 85 of 234
Servo Drive Connections:
Servo Drive Connection Details:
Page 86 of 234
10.0 CNC CUTVIEWER SOFTWARE
Hytech has developed an indigenous CNC controller based on PLC technology in collaboration
with CutViewer – United Kingdom. In Hytech machines, CutViewer is used as a CAM software.
CutViewer is one of the leading softwares in the world with global presence in 37 countries.
10.1 CutViewer Features
10.1.1 Full 3D Simulation, not just a toolpath viewer
There are lots of "CNC Simulators"

out there that don't simulate
anything- they just show you the
toolpath.
Your CAM program can show you

the toolpath but you need to see
what the finished part is going to
look like. Cutviewer shows you a full
3D simulation of the finished part
based on the toolpath, the stock you
define, and the cutters you're using.
10.1.2 Collision detection prevents catastrophes
Cutviewer detects any part of the

toolpath where the shaft of the
cutter touches the stock during a
cutting move or any part of the
tool touching the stock during a
rapid move.
Page 87 of 234
10.1.3 Reads all common G code formats
Cutviewer provides Emulation of

most of the widely used
controllers in India. It is specifically
designed for training and
educational institutes to give
students hands on experience on
various leading CNC Controllers.
Following controllers can be
emulated on CutViewer:
 Fanuc
 Siemens
 Heidenhain
 Deckel
 Fadal
 Dynapath
 Deckel
 Gildemeister
 Traub
 Okuma
 Anilam Crusader
 Haas
10.1.4 Use any kind of tool
User can define any type of tool

according to his requirement.
Cutviewer will ask the programmer
to define a tool in case if the
programmed tool is not defined by
the user.
Page 88 of 234
10.1.5 Measure the finished part without

having to cut a thing
Not sure if the finished part will be

dimensionally accurate? Cutviewer
lets you take measurements from
the simulated stock. You can:
 Take linear measurements
 Take angular measurements
 Look at cross-section curves
 Measure the volume of the
finished part
10.1.6 Built-in G code editor
As described before, CutViewer tells user if

there are any errors required in the program. If
you find any errors in your gocde there's no
need to open it up in an external editor to
make changes. You can edit the code directly
in Cutviewer and then redo the simulation to
see the results.
10.1.7 Machining Mode / Simulation

Mode
Cutviewer (Hytech CNC) has two

modes namely Machining mode and
simulation mode. In simulation mode,
user can see the 3 Dimensional
simulation of the part program. In this
mode, there won’t be any movement
of the machine. In case of machining
Page 89 of 234
mode, user can see the simulation

along with machine movement.
10.1.8 Other CutViewer Features:
1) Powerful Graphic user interface.

2) All the programming codes are compatible to the Fanuc – 0T Model.
3) On-line 2-D & 3-D simulation
4) On-line program Editing facility.
5) Single Block / Dry Run Facility
6) Software based Spindle speed over-ride & Feed over-ride.
7) Program execution in Auto, Single Block & Selected Block mode.
8) Print option with 2-D simulation & program.
9) Automatic calculation for G02 & G03 codes.
10) On line programming help facility.
11) Programmable Hardware addresses.
12) Comments in the program can be added by ‘ ( ‘ bracket.)
13) Manual Data Input facility. Automatic Job diameter & length setting by “[BILLET”
command]
14) Can be upgraded to fullfledged FMS system
10.2 CUTVIEWER TURN SOFTWARE
What is CutViewer Turn?
Cutviewer Turn V3.1 is an easy to use program that graphically displays the material removal
process for turning operations in 2 axes. Based on the stock statements and tool definitions,
Cutviewer will show you exactly what material will be removed from a raw stock. It will also
help you to determine the final dimensions as well as final shape of the machined component.
What Hardware does CutViewer Require?
CutViewer is a 32 bit application. For machine compatible CutViewer software, Windows XP

operating system is a must. The hardware minimums include a Pentium processor, 32 MB of
RAM, 100 MB of hard disk space, and a video graphics card with at least 256 MB of video RAM.
Display Settings before running CutViewer, set the Windows Color Palette to 16-bit mode
(65535 colors) or higher. The raw stock can be defined as either a simple cylinder or a free
shape stock. Stock and tool data can be included in your NC program, or defined separately
prior to running the program.
Page 90 of 234
 User can define any tool that he desires. There is no limitation on the tool type as well as
number of tools.
10.2.1 Running CutViewer
When you first open CutViewer it appears as a reduced size window. You can maximize the
main window but take into account that window size affects the run speed. Screen layout
contains 2D View window, 3D View window and the Edit window.
All windows are empty when they appear. You can close or add 3D View window through the
‘View menu’ in the menu bar. Edit window is located at the bottom of the screen by default
but you may change the Edit window location (Top, Bottom, Left, Right) via Setup in the
menu bar.. You may also change the orientation of 2D/3D View windows (Vertical or
Horizontal).
After starting CutViewer only the File-New, File-Open, and Setup items are available. To load a
file, select the Open File button and navigate to the desired directory. Select the appropriate
filter in the “Files of type” combo-box to tell CutViewer which configuration to use to
interpret the g-code.
*Important: selecting wrong configuration causes incorrect simulation (e.g. if you open Fanuc
NC file selecting Okuma configuration).
Page 91 of 234
If stock and tool information has not been added to the NC post file beforehand, a series of
dialogs will prompt you to define them when the NC file is loaded. CutViewer maintains tool
database files in the CutViewer directory for each type of tool you choose to save there.
These tool database files have a *.db2 extension. You can store and retrieve these tools for use
in all of your simulations.
When finished, the Editor window will display the NC file and a shaded Stock will be shown in
2D/3D View windows. The stock can be shown either as unsectioned model or as a quarter
section or as a half section. 2D View is set to Half Section and 3D View to “No Section” mode
but you can change this through the window popup menu (in order to open the menu the
user should click with the mouse right button somewhere on the window area).
Pay attention that Tool Path and Tool image will be shown only in 2D View window. Before
starting simulation you can select desired scale, position and Section mode for each view
through popup menu items (Zooming, Panning, Rotation, Sectioning), but take into account
that CutViewer automatically switches 2D View to Half Section mode after pressing the "Run"
button. You may switch 2D View back to "No Section" or "Quarter Section" mode after the
simulation is completed or paused or stopped.
Page 92 of 234
Press the "Run" button and 2D View will be automatically switched to the Half Section and the
animated cuts will appear on 2D view. You can also switch 3D view to animated mode but this
reduces the run speed.
To make the on screen cutter speed slower you can define 'Dwell' value (milliseconds) in
'Setup' mode and the process will be suspended for the specified dwell time at every screen
point of the tool motion.
To make the cutter move faster during processing simply press '+' key
and press the '-' key to slow it down. Press 'Pg Up' key for the fastest cutter speed.
There are two modes of simulation accessible through Setup:
1. Animated: Graphically simulates the material removal process by updating the stock
solid shape as the tool moves (by default).
2. Turbo: Graphically updates only the tool path with the tool image. The machined part
appears only after reaching the end of NC file or when the user presses 'Step Forward', 'Pause'
or 'Stop' button.
If you want to create new NC program directly in the CutViewer select the “File-New” menu
item, then select the desired CNC type and an empty Noname.nc file will be loaded to the Edit
window. Now you can type the program. To save new program to the disk select the “File-
Save as” menu item. To simulate new program select the “Run-Rebuild” menu item or simply
press Ctrl-F9. If Tool or Stock info are omitted then Cutviewer will initiate the appropriate
dialog prompting for missing info.
10.2.2 Command Bar Functions:
Open File
This is for opening NC file from a folder or across network. But make sure you select the
appropriate filter in the “Files of type” combo-box to tell CutViewer which configuration to
use to interpret the g-code.
Page 93 of 234
Step forward/backward
Switches to step-by-step mode, as this button is pressed repeatedly, the tool moves
incrementally forward or backward. When in Step mode, the line being executed will be
highlighted in the Edit window and a separate dialog will display the current coordinates and
cutting parameters. This helps in identifying the lines to edit. To cancel the incremental trace
mode press the 'Run' button.
Note: you can simply press the 'Space' key instead of the 'Step' button for step-by-step
motions and the 'Return' key to cancel the incremental trace mode.
Pause
Suspends execution. While processing is paused, you may apply zooming, measure the part as
well change the Setup parameters and EDIT the code. The 'Run' button will restart simulation
from the paused position with provision for new parameters. You can also edit the file, but
you have to select the "Run"-"Rebuild" menu item or press Ctrl-F9 in order to implement the
changes.
Stop
Stops execution of the simulation. Unlike 'Pause', you cannot restart from the current position
after pressing 'Stop'. Pressing 'Run' following 'Stop' will start the simulation from the
beginning of the file. Also press 'Run' following 'Stop' if you want to restart process after finish
of the simulation.
Dynamic Zoom
Allows for dynamic zooming of the model with the left mouse button. To use this function
click the button then hold down the left mouse button while using the mouse and the view
will change.
Zoom Window
Allows for the zooming by a window or region selection method. To use this function, click
the button and while holding down the left mouse button select the desired window and
then release the mouse button.
Zoom Fit
Press this button to fit the whole part in the window.
Zoom Previous
Reverts to the previous zoom view.
Pan
Page 94 of 234
Moves the part within the window. Press the button, and then hold the left mouse button
down while moving the mouse. When the view is in the desired position release the mouse
button.
Rotate
Rotates the view. Press the button, then hold the left mouse button down while moving the
mouse. When the view is in the desired position release the mouse button. This mode is
available for 3D view only.
Measurements
Displays a tool for making measurements of the part. All measurements are available in 2D
View only.
Setup
Launches a dialog where you can configure how CutViewer works. If you press the save
button to exit rather than the OK button your settings will be the default the next time you
launch CutViewer.
10.2.3 Tool and stock definition
As CutViewer Lathe loads an NC file, it looks for information about the stock size, tool
geometry and program origin placement relative to the stock origin. This requires the addition
of several lines to the NC file. If these lines are omitted from the NC file, CutViewer will
initiate a sequence of dialogs prompting for the missing information. If you prefer to insert
the lines manually follow the directions below:
Each NC file must contain following additional lines: STOCK, FROM, and TOOL. Tool, Stock and
From definition lines should be prefixed with a semicolon, left parenthesis or the character
your CNC controller uses for a comment line.
If the Stock shape is a Cylinder with a hole, the command for Stock definition is as follows:
STOCK/L,D1,D2,Z
L - Stock Length
D1 - Cylinder Diameter
D2 - Hole Diameter
Z - Origin Z
Page 95 of 234
The stock reference point (origin) is the center of the right face. Origin Z indicates the z
position of the program origin relative to the stock origin.
If the Stock has more complicated shape than cylinder it may be defined by sequence of G-
code lines prefixed with the character your CNC controller uses for a comment line. This
sequence must be placed between STOCK/BEGIN and STOCK/END commands.
For example if the Stock has a shape as on picture below and the points 1-7 have Z, X -values
as follows:
1. Z=80 X=20
2. Z=80 X=40
3. Z=40 X=40
4. Z=30 X=60
5. Z=30 X=85
6. Z=0 X=85
7. Z=0 X=20
Page 96 of 234
The Stock statement for FANUC control may be as follows:
;STOCK/BEGIN
;G1 Z80 X20
;Z80 X40
;Z40 X40
;G2 Z30 X60 R10
;G1 Z30 X85
;Z0 X85
;Z0 X20
;Z80 X20
;STOCK/END
The machined stock can be saved to the disk through “File-Save Part as Stock” menu item and
then you can verify next operations on this stock. For example if you have 2 separate NC
programs for roughing and finishing you can save machined stock after roughing to the file
and then use this stock for finishing NC program.
To load Stock from the file use the following command:
;STOCK/File, File Name, Orientation, Origin
FileName is the name of file where the machined Stock was saved.
Orientation is a number +1 or –1 and tells CutViewer if the Stock remains its original Z direction
or should be turned around 180 deg.
Page 97 of 234
Origin is Z position of Program Origin relative to the Stock Origin.
The machined stock can be also saved to the disk as STL-file through “File-Export to STL” menu
item. It may be useful for those users who want to verify next milling operations on this stock
using the appropriate software from third parties.
10.2.4 Tool Definition
10.2.4.1 Standard OD tool:

TOOL/STANDARD, BA, A, R, IC, ITP
TOOL/STANDARD, BA, A, R, IC, ITP
Note: The IC (Inside Circle) is the diameter for which the tool insert geometry is created about.
The IC is an industry standard term used by all insert manufactures.
The ITP (Imaginary Tool Point) is the intersection of the vertical and horizontal edges of the
tool and this point often is used for Tool Path programming.
Page 98 of 234
The ITP is a value indicating the tip position of the Imaginary Tool Point with respect to the
Tool Nose Radius Center Point as illustrated below.
ITP=0 if the Tool Nose Radius Center Point is used for ToolPath programming.
10.2.4.2 Button OD Tool:
TOOL/BUTTON, R, L, W, OA, ITP

OA=90 (orient angle)
10.2.4.3 Button ID Tool:
TOOL/BUTTON, R, L, W, OA, ITP

OA=270
10.2.4.4 Grooving OD tool:
TOOL/GROOVE, R1, R2, L, W, A1, A2, OA, ITP

OA=90
Page 99 of 234
10.2.4.5 Grooving ID tool:
TOOL/GROOVE, R1, R2, L, W, A1, A2, OA, ITP

OA=270
For Face tool OA=0
Note: To change control point (left or right tool corner) simply change sign of W value.
10.2.4.6 Threading OD tool:
TOOL/THREAD, A, L, W, OA
Page 100 of 234

10.2.4.7 Threading ID tool:
TOOL/THREAD, A, L, W, OA
10.2.4.8 Drill:
TOOL/DRILL,D,A,L
Note: You can insert a new tool into the NC file at the needed position. To get the Tool
definition dialog choose “Insert Tool definition” from the Edit window context menu. After a
Tool line is inserted, you have to select the "Run"-"Rebuild" menu item or press Ctrl-F9 in order
to implement the changes.
You can add a new tool to the database of tools. Simply press the "Add tool to DB" button
from the Tool definition dialog. Afterwards you can get the tool from this database pressing
the "Get Tool from DB" button.
You can assign display color to each tool using the command:
COLOR, R, G, B
This command must follow the TOOL Command.
R - specifies the intensity of the red color
G - specifies the intensity of the green color
B - specifies the intensity of the blue color
The intensity for each argument is in the range 0 through 255.
Page 101 of 234

If all three intensities are zero, the result is black.
If all three intensities are 255, the result is white.
For example, you may type the following:
COLOR, 0, 255, 0 - Display Color is green;
OR
COLOR,255,255,0 - Display Color is yellow;
Note: CutViewer inserts Color line automatically if you use Tool definition dialog. You can
change Display Color for each tool pressing the color assignment button in "Setup" mode or
directly using a simple key-combination "Ctrl-T". To change the color, simply click on the
appropriate cell in the "Color" column.
FROM/Z start, X start
The FROM line denotes the starting or home position of the tool relative to the program
origin.
For example:
;FROM/0,60
Note: Any leading symbols are permitted, provided they do not interfere with program
execution.
For example, you may type the following:
FROM/0,120
or
FROM/0,120
10.2.5 Editing
You can modify an NC program in the Edit window, as you would edit a file. All changes will
be accepted only after you select the "Run"-"Rebuild" menu item or press Ctrl-F9 for program
rerunning.
For program debugging you can select the menu item "Run"-"Run to Cursor" or simply press F4
key. The "Run to Cursor" command runs your program from the current point to the line the
cursor is on in the edit window and then switches to the Step-by-Step mode. For example, if
you are checking a large NC file you may select fast Turbo mode of operation then select the
desired line in the edit window and press F4. When the program stops at selected line you can
Page 102 of 234
switch to the Animated mode and continue processing. You can also use Ctrl-F4 after
modifying the program. This would be the same as "Rebuild" and "Run to Cursor".
You may also set breakpoints on lines in the NC file where you want the program execution to
pause during a run. Running to a breakpoint is similar to Running to a cursor position in that
the program runs until it reaches a certain line. However, unlike Run To Cursor, you can have
multiple breakpoints in your file. To set a breakpoint, select the line in the file where you want
the breakpoint set, then do one of the following:
a) Press F5
b) Choose Toggle Breakpoint from the Run menu
c) Choose Toggle Breakpoint from the Edit window context menu.
When you set a breakpoint, the line on which the breakpoint is set becomes highlighted.
*Note: you can select Edit commands through popup menu. In order to open thiss menu the
user should click with the mouse right button somewhere on the Edit window area.
10.2.6 Zooming
Use one from the following buttons for zooming:
Dynamic Zoom
Allows for dynamic zooming of the model with the left mouse button. To use this function
click the button then hold down the left mouse button while using the mouse and the view
will change. When the view is in the desired position, press the right mouse button to leave
“Dynamic Zoom” mode.
*Note: you can enact the "Dynamic Zoom" command directly using a simple hot key without
pressing a button. Press the Shift key and click-drag with the left mouse button.
Zoom Window
Allows for the zooming by a window or region selection method. To use this functions click
the button and while holding down the left mouse button select the desired window and
then release the mouse button.
Zoom Fit
Page 103 of 234

Press this button to fit the whole part in the window.
Zoom Previous
Reverts to the previous zoom view.
10.2.7 View Rotation
For view rotation press the 'Rotate' button. To rotate the view, hold the left mouse button
down while moving the mouse. When the view is in the desired position, press the right
mouse button to leave “Rotation” mode.
*Note: you can enact the "Rotation" command directly using a simple hot key without pressing a
button. Press the Alt key and click-drag with the left mouse button.
10.2.8 View Panning
For view panning press the 'Pan' button. To pan the view, hold the left mouse button down
while moving the mouse. When the view is in the desired position, press the right mouse
button to leave ‘Pan’ mode.
*Note: you can enact the "Panning" command directly using a simple hot key without pressing
a button. Press the Ctrl key and click-drag with the left mouse button.
10.2.7 Settings
Through the 'Setup' button you can change and save the following
System parameters:
Mode of Simulation:
1. Animated: Graphically simulates the material removal process by updating the stock solid
shape as the tool moves (by default).
2. Turbo: Graphically updates only the tool path with the tool image. The machined part
appears only after reaching the end of NC file or when the user presses 'Step Forward', 'Pause'
or 'Stop' button.
Page 104 of 234

Update 3D View after each motion: enables or disables the animation in 3D view. This item is
unavailable for Turbo mode.
Draw Tool : enables or disables the tool on screen image.
Draw ToolPath : enables or disables the ToolPath on screen image.
Dwell (milliseconds) : dwell at the every screen point of tool motion for slowing the
on screen tool speed
Check Rapid Collision : enables or disables the detection of Rapid Collision. If this option
is on then Cutviewer graphically simulates any collision the tool has with the stock material
while under Rapid Traverse. Execution of the NC file will stop at the block of code where the
collision occurs and a special dialog box will also appear that will display the coordinates for
the current type of move in a from-to format and the buttons to define next actions. You may
continue execution, pause or stop it. If you press the “Ignore All” button then execution will
continue but without any Rapid Collision detection’s or in other words the option “Check
Rapid Collision” will be Off. That’s why don’t forget to turn “Check Rapid Collision” to On if you
want to have this feature being available for further simulations in the same session.
.Axis Direction : setting X, Z axis orientation in 2D view.
Edit window position : setting position of the Edit window in the main program
window.
2D-3D Window orientation: setting the Vertical or Horizontal orientation of 2D-3D View
windows.
Color : setting color palette.
Note: When CutViewer loads NC file, it creates a record in memory of any tool size or tool
color statements that have been inserted where the tools take effect. A different color
statement can optionally follow each tool definition.
If no color statements are found in the post, CutViewer uses the “Part color” shown in the
Setup dialog. Changes made to tool colors by means of the setup dialog will persist only if
there are no colors assigned in the NC file. A Ctrl-T key combination will directly launch the
tool color dialog.
Reloading the NC file (Rebuild – Ctrl-F9) will cause the program to use any colors added to
the editor buffer and override changes made in memory through the setup dialog. Once the
NC post is loaded into memory the tool colors can be changed in the setup and seen
immediately.
So, for a permanent color update we should add COLOR commands to the NC file.
Page 105 of 234

10.2.8 Customizing
Cutviewer uses a simple text file with an *.nci extension to configure CutViewer for specific
style of post. The nci file uses the same format the common .ini file. These files are kept in the
CutViewer install directory. The *.nci configuration file defines the extension filter and
description that appears in the combo-box in the open file window. The extension filter can
be used to limit viewing only those files for which the configuration file is correct.
The default configuration file called _gcode.nci may be found in the CutViewer directory. If
you have only one NC machine simply edit this file. If you start by editing the default file it
would be a good idea to save the original before editing.
Several sample *.nci files are provided with the program and can be used to view some demo
posts. Move any move any of these sample nci files to another directory to shorten the list of
choices in the file open combo-box.
If you have several machines, make copies of _gcode.nci under different names in the
CutViewer directory and edit these files. Notepad or WordPad can be used to edit them.
When saving these files, make sure the file is saved as FileName.nci and not as FileName.nci.txt
(Notepad is notorious for this).
Note: A backup of the default _gcode.nci is also found under the name _G code. defined
To load an NC file into CutViewer you must select the correct configuration file from the “Files
of Type” combo-box in the file open dialog when you load a file.
Creating new NCI files
There are two required sections in this file:
[Common]
[Format]
NCI files are not case sensitive. Only the settings that are used by your program need to be in
the file.
Comments have been added above each setting in a different font to show that they are not
needed in the file.
A sample nci file looks like this:
[Comments]
A description that, when seen in the combo=box, will help describe what kind of post the
configuration is for.
CNC=Fanuc FOTA
The extension filter, which is used by the open file window to filter the file list, should be the
same as what appears in you NC post filename.
FileExt=*.nc
Note: multiple extensions are allowed. Example: FileExt=*.nc;*.cnc
The character that the post uses before a line that tells the machine controller not to interpret
that line is,
Comment_chr=(
The word Inch or Metric, depending on which unit scheme will be used in the NC post file.
Units=metric
Page 106 of 234

[Format]
The next 2 settings define the coordinate symbols
x_addr=X
z_addr=Z
The next 2 settings define the ratio X,Z value in NC file to actual value of X,Z coordinates:
x_scale=2
Z_scale=1
i.e. if X address in NC file is the Diameter value then x_scale=2
if X address in NC file is the Radius value then x_scale=1
The next two settings define how arc centers are read when either G90 or G91 is active and
only apply to a G02/G03 line that has a center defined with I J K words but not when X Z R is
used.
IJKformat_abs=
IJKformat_incr=
There are exactly 5 different string values that can be used with each:
I and K are absolute Center.
I and K are incremental from the XZ end point of the arc
end-center.
I and K are incremental from the start point of the arc
center-start.
If the control expects that incremental centers are always a positive number an “abs” is added.
abs(end-center)
abs(start-center)
If G90 active
Ijk format abs=
If G91 active
Ijk format_incr=
Example:
Ijk format_abs=end-center
Ijk format_incr=abs(end-center)
The feed rate symbol
f_addr=F
The RPM symbol
s_addr=S
The tool symbol
tool_addr=T
The feed rate that above which rapid color is displayed and collision is expected if the cutter
has met material.
f_rapid=5000
Cutter compensation g-codes.
cutcom_left=G41
cutcom_right=G42
Page 107 of 234

cutcom_off=G40
Please note that if your CAM system is posting profiles using the cutter centerline instead of
the part profile, each one of these should be set to “Gxx” so that they are ignored when
encountered.
The end of the main program
prog_end=M30
Sub routine call
sub_call=M98P
Begin sub definition
sub_begin=O
End sub definition
sub_end=M99
Sub repeat character
sub_repeat=L
Example of a _gcode.nci file :
[common]
CNC=Standard G-code
fileExt=*.nc
comment_chr=;
units=metric
[format]
x_scale=2
z_scale=1
f_scale=1
s_scale=1
IJkformat_abs=end-center
IJkformat_incr=abs(end-center)
x_addr=X
z_addr=Z
f_addr=F
s_addr=S
tool_addr=T
f_rapid=3000
cutcom_left=G41
cutcom_right=G42
cutcom_off=G40
prog_end=M30
sub_call=M98P
sub_begin=O
sub_end=M99
sub_repeat=L
Page 108 of 234

10.2.9 Custom Control Conversion
Some CNC have a canned cycles and special functions that can’t be defined via variables in
NCI-file. In this case the user should develop his own converter.
If there is the following line at [format] section in the nci-file:

user_convert=mycoverter.dll
then first of all CutViewer will try to call the procedure named User_convert_proc from
myconverter.dll file. User_convert_proc procedure has 2 parameters - input file name and
output file name. These parameters CutViewer passes to your procedure. If you write your
programs on Delphi the declaration for the procedure in DLL looks as follows:
Procedure user_convert_proc(infile,outfile:pchar);stdcall;
Input file is NC-file to be converted and output file is a result file with
standard G-codes. In other words CutViewer calls the procedure
user_convert_proc passing 2 parameters and expects that your procedure will
create output file with the name passed by "outfile" parameter and then
CutViewer handles this file as usual. There is one rule for output file.
Every line in this file should be prefixed by number and "#" symbol.
Example:
.....................
10# G01 X1 Y1
11# G00 Z5
14# T1
15# G01 X1 Y0.5 F2
............................
Number before "#" symbol means that current line in the output file is
corresponding to the line in input file with the index defined by this
number (first line in the input file has the index 1) .
Let me explain.
We should convert NC-file for hypothetical CNC that has the following
format:
TOOLNO, 1
SPINDLE, 500
RAPID
GOTO/X=1,Y=2,Z=5
FEEDRATE, 20
Page 109 of 234

GOTO/X=1,Y=2,Z=1
FIN
This is the input file. Our procedure creates the appropriate output file
with the following standard G-codes:
1# T1
4# G00 X1 Y2 Z5 S500
6# G01 Z1 F20
7# M02
You see that number before # is the appropriate line index for input file.
CutViewer needs this index to provide correct cursor navigation in the edit window during
step-by-step mode because the first file will be loaded into the edit window but in fact
internally CutViewer works with the second file.
The algorithm how to convert input file into output file or in other words
the program code inside the procedure is your responsibility and of course
this file in details can be different for different developers. For example
you can create the following output file in our case:
1# T1
2# S500
4# G00 X1 Y2 Z5
5# F20
6# G01 X1 Y2 Z1
7# M02
You can also create exe file instead of DLL and the line in NCI-file in
this case is as follows:
user_convert=myconverter.exe
In this case at first CutViewer runs myconverter.exe file and passes 2
parameters through command line (input and output file names). Your program
should accept these parameters and create the appropriate output file.
10.2.10 Supported codes for Fanuc F0TA and F10TA, F11TA
You can find the samples of NC program for Fanuc after installing CutViewer Turn in the
“FANUC F0TA Samples” and the “FANUC F11TA Samples” folders. Pay attention all samples are
in the Metric units. If your NC programs for Fanuc are in inches please change the Units
variable in fanuc.nci and Fanuc1.nci files as follows:
Units=inch
Page 110 of 234

Also pay attention to some difference in the cycle definition for Fanuc F0TA and F10TA, F11TA
controls.
SUBPROGRAM CALLS
When a program contains certain fixed sequences or frequently repeated patterns, these
sequences or patterns may be entered into memory as a subprogram to simplify
programming. A subprogram can call another subprogram. When the main program call a
subprogram, it is regarded as a one-loop subprogram call.
When a command calling a subprogram is encountered in the main program control is passed
to the subprogram. And control returns to the main program when returning command M99 is
encountered in the program.
Format : M98 P__ O__
Where,
P = subroutine repetitions.
O = subroutine label (numerical).
There is a communication link between actual machine and the computer. Computer
sends commands to the Machine controller as well as at the same time it receives the status
of machine and its operations.
To control the machine operations, software makes the use of I/O channels supplied with
computer using I/O card. Input and output commands from computer are routed through the
I/O card to the controller and then to machine. Software reads the status of machine in real
time.
Page 111 of 234

11.0 GETTING READY WITH SOFTWARE:
CutViewer is fully menu driven for ease in learning. The Display and functions are arranged in
the same way as regular CNC machine console.
After loading the software it performs the self diagnostics as well as the machine diagnostics.
If there is any kind of malfunctioning it will display the Error Alarms and will guide the user.
The main menu will be displayed on the left side of the screen. This will have following
options,
1] File
2] Edit
3] Running
4] View
5] Section
6] Rotate
7] Zoom
8] Utility
9] Mode
10) Measurements
11] Help
As you start the software by selecting
StartprogramCutviewer turn Cutviewer_Turn
You will get following window
In this window
This region is main menu
Page 112 of 234

11.1 About Cutviewer software:
To run the software the EXE file is Cnclwin. It will take you to the main screen of the software
as shown below.
You will see three windows here.
The left side window is for 2-D view & it also acts as a status window when a program is
executed. The X & Z co-ordinate values will be updated according to program. This value is the
current tool position. This can be changed in the program or by selecting the tool by the
button near to tool no. The jog is used actually for initial tool positioning on the CNC lathe
machine. So it is not required for the simulation purpose. You can select the no. of pulses &
move the tool by pressing the direction buttons. The model code is the basic code, which is
used in the program. This code is changed according to program. The default code is G00. The
coolant , spindle & lubrication motor can be started manually by selecting the window
provided with it. As stated earlier these are also updated according to program.
The spindle is provided with the speed over-ride window. The spindle value is changed
according to program but can be varied with this feature. Same is the case for feed over-ride
window. The feed value is nothing but the speed of the cutting tool in mm/min.
The MDI (manual data input) is not a part of the simulation software.
The window at the top of right side is an editor window. When a CNC program is loaded from
the existing files, the program containing various G, M & other codes is seen in this window.
Here you can edit the program that means you can change any code, you can add or delete a
line & the main feature about this window is that you can do all these operations at the time
of program execution also. During simulation the current executing block is highlighted & the
program is scrolled.
The third window at the bottom is for 2D simulation of the cnc program. You will have to
define the job size i.e. job diameter & job length according to your program & when the
Page 113 of 234

program is executed the simulation will take place. The tool picture is changed when it is
changed in the program.
The size of the program editor & the simulation window can be changed.
The menus at the top:
The main menus of this software are File, Edit, Program, Settings, View & Help.
When file menu is selected the following screen is displayed.
11.2 FILE MENU:-
Here you can see various menus, which are very similar to the normal menus seen in MS-
Office or other softwares. With ‘New’ you can create a blank file, which is seen in the editor
window. Now you can start writing the CNC program. You can save the program by giving a
name & the location.
The already saved program in the memory can be seen by ‘Open’ menu. The loaded file can be
saved by another name with Save As menu.
The CNC program must be written in a fixed format. The printing option is somewhat different
from the regular pattern. Here first the program should be executed then print command is
given. So in printout you will see the final 2D shape of the job & the part program below that.
Below print menu the previous loaded programs can be seen.
11.3 EDIT MENU :-
The Edit menu is used mainly to modify the program. It has the various menus such as Undo,
Cut, Copy and Paste. You can also Find the required word directly from this Menu or Replace
any word from this Menu. The ‘Edit’ menu has different options, which can be seen in the
following picture:
Page 114 of 234

11.4 VIEW MENU:-
This menu is used to see the program in Different views Like In 2D View or in 3D View.
2D VIEW:-
3D VIEW:
Page 115 of 234

11.5 RUN MENU:-
The ‘Run’ menu is seen like this:
‘Run’ and ‘Rebuild’ command are functionally the same at the start of the program. If user stops
the program, user can restart the program from the same point by ‘Run’ command. ‘Rebuild’
command will completely restart the program.
‘Run to cursor’ will run the program till the cursor and ‘Rebuild to cursor’ will rebuild the
program till cursor.
11.6 ZOOM MENU:-
In this menu we can zoom the job as per convenience. In this First select the zoom menu.
Then, select zoom window / zoom fit, and then select the area to zoom with the help of a
cursor.
11.7 PAN MENU:-
In this menu you can move the job in both the views i.e. in 2D view & 3 D views.
Page 116 of 234

11.8 ROTATE MENU:-
In this menu we can rotate the job as per convenience. First select the rotate menu and then
by just clicking the cursor rotate the job.
In this menu the job will rotate in only 3-D view.
11.9 SETUP MENU:-
In this Setup menu we can set the Background color, Different Views of the jobs i.e. Isometric
View, Top View , as per our convenience. In this First select the Setup menu and then the
setup Screen will display on the Screen.
We can Also check the Rapid Collision of the tool. In this we can also add the Dwell in
microseconds.
11.10 MODE:
There are two different Modes:
1. Simulation Mode
2. Machining Mode
By default, system goes to ‘Machining Mode’. In this mode, commands are transferred to
Controller and machine movements take place.
In ‘Simulation Mode’, user can see the simulation on screen and there would be no machine
movement.
While making a new program, ideally user execute the program in ‘Simulation Mode’ to check
if there are any errors in part program. Once convinced, user should run the program in
‘Machining Mode’.
11.11 MEASUREMENTS
Measurement window can be opened by clicking on Measurement icon

Page 117 of 234
Following window represents all measurement options:
Diameter Linear Distance
Angle
Arc Info
Line Info Vertex Info
Line – Line
Intersection Line – Arc Intersection
Arc - Arc
Tool Path Info
Intersection
Machining
Time, Volumes
11.12 HELP MENU:-
Help menu is for on-line help when you are using the software. It will give you information
about various menus like Programming codes, about machine parameters or about software
details.
Page 118 of 234

12.0 CNC PROGRAMMING G & M CODES
12.1 G Code List
SR.NO. G CODE FUNCTION
1 G00 RAPID POSITIONING
2 G01 LINEAR INTERPOLATION
3 G02 CLOCKWISE CIRCULAR INTERPOLATION
4 G03 COUNTER CLOCKWISE CIRCULAR INTERPOLATION
5 G04 DWELL IN SECONDS
6 G20 INCH PROGRAMMING
7 G21 METRIC PROGRAMMING
8 G28 AUTO. RETURN TO REF. POINT
9 G32 THREAD CUTTING CYCLE
10 G70 FINISHING CYCLE
11 G71 STOCK REMOVAL IN TURNING
12 G72 STOCK REMOVAL IN FACING
13 G73 PATTERN REPEATING CYCLE
14 G74 PECK DRILLING CANNED CYCLE
15 G75 GROOVING CYCLE.
16 G76 TAPER THREADING CYCLE.
17 G90 DIAMETER CUTTING CYCLE
18 G92 THREADING CANNED CYCLE
19 G94 FACING CYCLE.
20 G96 CONSTANT SURFACE SPEED ON
21 G97 CONSTANT SURFACE SPEED OFF
Page 119 of 234

12.2 M Code List:
SR. NO. CODE FUNCTION
1 M01 OPTIONAL PROGRAM STOP
2 M02 PROGRAM END
3 M03 SPINDLE START CLOCKWISE
4 M04 SPINDLE START ANTICLOCKWISE
5 M05 SPINDLE STOP
6 M07 COOLANT NO. 1 ON
7 M08 COOLANT NO. 2 ON
8 M09 COOLANTS OFF
9 M13 SPINDLE CLOCKWISE & COOLANT ON
10 M14 SPINDLE ANTI-CLOCKWISE & COOLANT ON
9 M30 PROGRAM END & REWIND
10 M98 START OF SUBROUTINE
11 M99 END OF SUBROUTINE
Page 120 of 234

13.0 Description of G Codes
13.1 Linear interpolation
13.1.0 Linear interpolation with rapid traverse: G0
The rapid traverse movement G0 is used for fast positioning of the tool, however, not for
direct workpiece machining. All axes can be traversed simultaneously - on a straight path.
For each axis, the maximum speed (rapid traverse) is defined in machine data. If only one axis
traverses, it uses its rapid traverse. If two axes are traversed simultaneously, the path velocity
(resulting velocity) is selected to achieve the maximum possible path velocity in consideration
of both axes.
Any programmed feedrates (F word) are not relevant for G0.
G0 remains active until canceled by another instruction from this G group (G0, G1, G2, G3, ...).
13.1.1 FeedRate
The feed F is the path velocity and represents the value of the geometric sum of the velocity
components of all axes involved. The axis velocities are determined from the share of the axis
path in the overall path.
The feedrate F is effective for the interpolation types G1, G2, G3, and is retained until a new F
word is written.
Unit of measure for F with G94, G95:
The dimension unit for the F word is determined by G functions:
● G94 F as feedrate in mm/min
● G95 F as feedrate in mm/rev. (only relative to the spindle speed!)
13.1.2 Linear interpolation with feedrate: G1
The tool moves from the starting point to the end point along a straight path. For the path
velocity, is determined by the programmed F word. All the axes can be traversed
simultaneously.
G1 remains active until canceled by another instruction from this G group (G0, G2, G3...).
See the following illustration for linear interpolation with G1:
Page 121 of 234

Example:
N05 G54 G0 G90 X40 Z150 S800 M3 ; The tool traverses in rapid
traverse, spindle speed=
800 r.p.m., clockwise
N10 G1 Z80 F0.6 ; Linear interpolation with
feedrate 0.6
mm/revolution
N15 X15 Z100
N20 Z80
N25 G0 X100 ; Retraction in rapid
traverse
N30 M2 ; End of program
Example 1:
// G71 Canned Cycle turning (Roughing)

// G70 Finishing Cycle
// Raw material size D25 mm x 100 L
N10 M03 S1800
N20 G00 X30 Z5
N30 G71 U1.0 R0.5
N40 G71 P50 Q120 U0.5 W0.5 F50 S1500
N50 G01 X10 f60
N60 G01 Z-8 F60
N70 G01 X15 Z-12
N80 G01 Z-21
N90 G01 X23 Z-33
N100 G01 Z-38
N110 G01 X25 Z-40
Page 122 of 234
N120 G01 Z-45

N130 G70 P50 Q120
N140 G01 X30 Z20
N150 M30
// U= Depth of cut in stock removal operation.
// R= Escaping allowance
// P = Start of Block
// Q= End of Block
// U = Allowance for X axis
13.1.3 Circular interpolation: G2, G3
The tool moves from the starting point to the end point along a circular path. The direction is
determined by the G function:
The description of the desired circle can be given in various ways:
Page 123 of 234

G 02
G 03
Meaning
Condition Instruction Right hand Left Hand
coordinate coordinate
G02 CW CCW
1 Rotation Direction
G03 CCW CW
X,Z Location X,Z of commanded point

Location of End Point
2 from coordinate Distance from start
Distance to the End Point
U,W point to commanded point
Distance between start point and

Distance from start point to the center
the center point I,K
of and arc with sign, radius value
3
Arc radius with no sign radius of
circumference R Radius of circumference
Page 124 of 234

G02 X(u) Z(w) R_ F_ :
G01 X30.0 Z60.0 F0.3

Z-25
G02 X40.0 Z-30.0 I5.0
(G02 U10.0 W-5.0 I5.0)
G01 X50.0
Z-60
Page 125 of 234

G03 X(u) Z(w) R_ F_ :
G01 X40.0 Z0 F0.3

G03 X50.0 Z-5 K-5.0
M30
Please Note:
1. If I or K is 0 it is omissible.
2. G02 I_: Make a round of circle.
3. It is recommended to use R as + value, and designates the circumferences less than 180.
G03 R_: No moving
4. When designating R which is less than the half of moving distance, override R and
make half circle.
5. When designating I, K and R at the same time, R is effective.
6. When the moving end point is not on the circumference, it is a result of wrong
designation of K value.
Page 126 of 234

Example 2:
User has to note that this example is only for understanding of G codes and noty to be
performed on Hytech machines.
M03 S2000
T1
G00 X0 Z3.0
G42 G01 Z0 F0.2 :
G03 X20.0 Z-10.0 R10.0 :
G01 Z-50.0 :
G02 X100.0 Z-74.385 I40.0 K20.615 : (G02 X100.0 Z-74.385 R45.0)
G01 Z-125.0 :
G40 U2.0 W1.0
G00 X200.0 Z200.0
M30
Page 127 of 234

Example 3:
User has to note that this example is only for understanding of G codes and noty to be
performed on Hytech machines.
M03 S2000
T1
G42 G00 X35.0 Z5.0
G01 Z-20.0 F0.2 :
G02 X67.0 Z-36.0 R16.0 : (G02 X67.0 Z-36.0 I16.0 K0)
G01 X68.0 :
G03 X100.0 Z-52.0 R16.0 : (G02 X100.0 Z-52.0 I0 K-16.0)
G01 Z-82.0 :
G40 G00 X200.0 Z200.0 M09 T0300 :
M30
Page 128 of 234

13.1.4 Threading (G32):
According to G32 command, straight thread and taper thread of certain pitch are cut.
G32 Z(w) F : (G32 is applied to only single block)
X(u) F :
Example 4:
Lead of screw : 3mm

d1 : 5mm
d2 : 1.5mm
Depth of cut : 1mm(2cut two
times)
(ABSOLUTE)
(COLOR, 255,255,255)
(TOOL/STANDARD, 40,40,0,10,3)
(STOCK/100,50,0,0)
// G32 Threading cycle.
//Job size Diam.25mm x 100L
G50 T01
G97 S800 M03 :
Page 129 of 234
G00 X90.0 Z5.0

X48.0 :
G32 Z-71.5 F3.0 :
G00 X90.0 :
Z5.0 :
X46.0 :
G32 Z-71.5 :
G00 X90.0 :
Z5.0
X150.0 Z150.0 T0100 :
M30 :
Example 5:
Lead of screw : 3mm

d1 : 5mm
d2 : 1.5mm
Depth of cut : 1mm (2cut two times)
(COLOR, 255,255,255)
(TOOL/STANDARD, 40,40,0,10,3)
Page 130 of 234

(STOCK/100,50,0,0)
// G32 Threading cycle.
//Job size Diam.25mm x 100L
G50 S800 T01
G97 S800 M03 :
G00 X90.0 Z5.0:
X22.026 :
G32 X49.562 Z-71.5 F3.0 :
G00 X90.0 :
Z5.0 :
X21.052 :
G32 X48.588 Z-71.5 :
G00 X90.0 :
Z5.0 :
X150.0 Z150.0 T0100 :
M30
Example 6:
(STOCK/45,25,0,0)
(TOOL/STANDARD,10,45,.1,10,0)
N1 M03 S3000( ----Spindle Start Clockwise With Spindle Speed 3000 )
Page 131 of 234
N2 G00 X25 Z0 ( ---- Rapid Positioning up to Reference point)

N3 G90 X24.0 Z-30 F70 (-- Diameter Cutting Cycle with 1mm (X) cut)
// up to -30 length (Z) With Feed F= 70 mm/min
N4 G90 X23.0 Z-30 F70 (-- Diameter Cutting Cycle with 1mm (X) cut )
N5 G90 X22.0 Z-30 F70( -- Diameter Cutting Cycle with 1mm (X) cut )
N6 G90 X21.0 Z-30 F70(-- Diameter Cutting Cycle with 1mm (X) cut ) )
N7 G90 X20.0 Z-30 F70(-- Diameter Cutting Cycle with 1mm (X) cut
N8 G90 X19.0 Z-30 F70(-- Diameter Cutting Cycle with 1mm (X) cut )
N9 G90 X18.0 Z-30 F70-- Diameter Cutting Cycle with 1mm (X) cut )
N10 G90 X18 Z-30 R-0.50 F70 (-- Diameter Cutting Cycle with 1mm (X)
cut )
N10 G90 X18 Z-30 R-1.0 F70
N16 G00 X35 Z20( ---- Rapid Positioning up to Reference point)
N17 M05( -------Spindle stop)
(TOOL/THREAD,40,25,10,90)
N18 T5( -------Tool change new tool no 5)
N19 M03 S800 (----Spindle Start Clockwise With Spindle Speed 800)
N20 G01 X19 ( ----------- Linear Interpolation)
N21 G01 Z2 ( ----------- Linear Interpolation )
N22 G76 P800 Q100 R0.2 (P :Height of thread, Positive radial value
in micron ,)
N23 G76 X16 Z-25 R-1.0 P800 Q100 F1 ( X :Last Diam . of Thread in
mm)
// ( Z : Absolute Z dimension of Threads )
// ( R: Radial difference between start of thread & end of Thread )
M30 ( Program stop and rewind )
// ( X :Last Diam . of Thread in mm)
// ( Z : End of Thread along Z axis )
// (P :Height of thread, Positive radial value in micron ,)
// ( no decimal point)
// ( Q : Cutting depth , Positive radial value in micron )
// ( R : Radial difference between start and End of Thread in mm)
Page 132 of 234
// ( For Straight Threads R =0 )

// ( F : Pitch of Thread in mm )
Example 7:
Turning, Drilling, Grooving and Threading

(STOCK/70,25,0,0)
(TOOL/STANDARD,40,40,0,10,3)
N001 M03 S3000
N010 T1
N020 G01 X25 Z0 F50
N030 G71 U0.5 R0.05
N040 G71 P50 Q70 U0 W0 F40
N050 G01 X15 Z0 F20
N060 G01 Z-20
N070 G01 X25 Z-35
N080 G70 P50 Q70
N090 G01 X30 F100
N100 G01 Z30 F100
(TOOL/GROOVE,.2,.2,25,4,5,5,90,0)
N110 T3
N120 G01 X16 Z-20
Page 133 of 234
N130 G01 X12 F1

N140 G01 X26 F100
N150 G01 Z-40
N160 G01 X22 F1
N170 G01 X30 F100
N180 G01 Z30
(TOOL/DRILL,8,90,50)
N190 T2
N200 G01 X0 Z2 F100
N210 G74 Z-15 Q5.0 R4 F10
N220 G01 Z35 F100
N230 T7
N240 M03 S500
N250 G01 X15 Z2 F80
N260 G32 X14.9
N270 G32 Z-18 F1
N280 G01 X15
N290 G01 Z2
N300 G32 X14.8
N310 G32 Z-18 F1
N320 G01 X15
N330 G01 Z2
N340 G32 X14.7
N350 G32 Z-18 F1
N360 G01 X15
N370 G01 Z2
N380 G32 X14.6
N390 G32 Z-18 F1
N400 G01 X15
N410 G01 Z2
N420 G32 X14.5
N430 G32 Z-18 F1
N440 G01 X15
N450 G01 Z2
N460 G32 X14.4
Page 134 of 234
N470 G32 Z-18 F1

N480 G01 X15
N490 G01 Z2
N500 G32 X14.3
N510 G32 Z-18 F1
N520 G01 X15
N530 G01 Z2
N540 G32 X14.2
N550 G32 Z-18 F1
N560 G01 X15
N570 G01 Z2
N580 G32 X14.1
N590 G32 Z-18 F1
N600 G01 X15
N610 G01 Z2
N620 G01 X25 F100
N630 G01 Z30
N640 M30
Page 135 of 234

Example 8:
Taper Threading
(STOCK/50,19,0,0)
//threading tool defination(A,L,W,OA)
//A= 55: thread angle.
//L=40mm: length of tool.
//w=6 width of tool.
//OA= tool angle
N18 T5 ( -------Tool change new tool no 5)
N19 M03 S500 ( --Spindle Start Clockwise With Spindle Speed
800)
N20 G01 X19 ( ----------- Linear Interpolation)
N21 G01 Z2 (----------- Linear Interpolation )
N22 G76 P000055 Q50 R5
N23 G76 X18 Z-25 R-1.0 P500 Q25 F1
( ---Taper threading with 1 mm pitch)
N24 G00 X25 Z10 (---- Rapid Positioning up to Reference point)
N25 M30 ( ------------ Program End & Rewind)
Page 136 of 234

Example 9:
Multi tool Operation
TEST SAMPLE -5 (MULTITOOL)
M03 S2000
M08
(STOCK/40, 22, 0, 0)
(TOOL/STANDARD, 10, 40, 0, 40, 3)
T1
G00 X22 Z2
G90 X21 Z-25 F100
G90 X20 Z-25 F100
G90 X19 Z-25 F100
G90 X18 Z-25 F100
G90 X17 Z-25 F100
G00 X25 Z30
M05
(TOOL/GROOVE, 0.2, 0.2, 30, 4, 0.3, 0.3, 90, 0)

T2
M03 S1500
G00 X18 Z-20
G01 X13
Z-20 F11
G00 X18
Z30
M05
T3
M03 S1500
G00 X0 Z0
G74 X0 Z-10 Q3.0 R2 F11
G00 X0 Z30
M05
Page 137 of 234

T4
M03 S500
G00 X17 Z0
G92 X16.9 Z-10 F1
G92 X16.8 Z-10 F1
G92 X16.7 Z-10 F1
G92 X16.6 Z-10 F1
G92 X16.5 Z-10 F1
G92 X16.4 Z-10 F1
G92 X16.3 Z-10 F1
G92 X16.2 Z-10 F1
G92 X16.1 Z-10 F1
G92 X16.0 Z-10 F1
G92 X15.9 Z-10 F1
G00 X20 Z30
M30
Page 138 of 234

Example 10:
I, K PARAMETER, G02 X24 Z-12 I0 K-12 F80
TOOL/STANDARD,15,55,0,10,3)
(COLOR,128,64,64)
(STOCK/80,25,0,0)
// Tool Definition (BA,A,R,IC,ITP)
//BA=15:Back rake angle,
//A=55: total angle between two side edges,
//R=0: Tool Nose radius.
//IC=10:Inside circle,
//ITP=3:ITP is a value indicating the tip position of the Imaginary Tool
Point with respect to the Tool Nose Radius Center Point.
Page 139 of 234

//Stock definition (L,D1,D2,Z),

//L=80:Stock length,
//D1=25:Cylinder Dia.,
//D2=0:Hole Dia.,
//Z=0:Zposition of program origin
//relative to stock origin.)
//Rod Dia. 25 X 80 Length in mm.
//Circular interpolation (CW) program by G02 command with I, K
parameter.
N01 M03 S2000 (-Spindle Start Clockwise With Spindle Speed

2000)
N02 G00 X25 Z2 (-Rapid Positioning Up to the Reference Point)
N03 G01 X24 F80 (-Linear interpolation up to specified point (X=
24) with feed 80mm/min)
N04 G01 Z-20 F60 (-Linear interpolation up to specified point (X=
24, Z-20) with feed 60mm/min)
N05 G01 X25 F80 (-Linear interpolation up to specified point (X=
N06 G01 Z0 F80 (-- Linear interpolation up to specified point (Z=
N07 G01 X22 F80 (--Linear interpolation up to specified point for
Start point of arc X=22, Z=0 with feed
80mm/min.)
Page 140 of 234

N06 G02 X24 Z-1 I0 K-1 F80 (--Circular Interpolation Clockwise up to

End point of arc i.e. X=24, Z-1. & I = 0 =
Distance between start point & center
point of arc along X-axis. K= -1 =
point of arc along Z-axis. Feed rate
80mm/min)
N08 G00 Z0 (-- Rapid Transverse up to reference point

(Z=0))
N10 G01 X20 F80 (--Linear interpolation up to specified
point for Start point of arc X=20, Z=0
with feed 80mm/min.)
End point of arc i.e. X=24, Z-2. &
I = 0 = Distance between start point & center point of arc along X-
axis. K=
-2 = Distance between start point &
center point of arc along Z-axis. Feed
rate 80mm/min)
(Z=0))
Page 141 of 234


End point of arc i.e. X=24, Z-3.& I = 0 =
80mm/min)
N20 G00 Z0 (-- Rapid Transverse up to reference
point(Z=0))
End point of arc i.e. X=24, z-4. & I = 0 =
80mm/min)
N26 G00 Z0 (--Rapid Transverse up to reference point
(Z=0))

point of arc along Z-axis Feed rate
80mm/min)
Page 142 of 234

N32 G00 Z0 (- Rapid Transverse up to reference

point(Z=0))
End point of arc i.e. X=24, z-6.& I = 0 =
point of arc along Z-axis feed
point.(Z=0))N40 G01 X10 F80 --Linear
interpolation up to specified point for
80mm/min.)
End point of arc i.e. X=24,z-7.& I = 0 =
N44 G00 Z0 (- Rapid Transverse up to reference point.
(Z=0))
point for start point of arc X=8, Z=0
point of arc along Z-axis feed rate
80mm/min)
N50 G00 Z0 (- Rapid Transverse up to reference point
(Z=0))
Page 143 of 234

N54 G02 X24 Z-9 I0 K-9 F80 (-- Circular Interpolation Clockwise up to
point of arc along X-Axis. K= -9 =
(Z=0))N58 G01 X4 F80 (--Linear
interpolation up to specified point for
80mm/min.)
N60 G02 X24 Z-10 I0 K-10 F80 (--Circular Interpolation Clockwise up
to End point of arc i.e. X=24,z-10.& I = 0
= Distance between start point & center
point of arc along Z-axis. Feed
N62 G00 Z0 Rapid Transverse up to reference point
(Z=0))
to End point of arc i.e. X=24, z-11. & I =
0 = Distance between start point &
center point of arc along X-axis. K= -11
point of arc along Z-axis. Feed
(Z=0))
to End point of arc i.e. X=24,z-12.& I = 0
80mm/min)
N74 G00 X25 Z2 (-Rapid Transverse up to reference
Point(X=25, Z=2))
N76 M30 (---------------Program End & Rewind)
Page 144 of 234

The simulation for the above example is shown below:
Part Programming codes that are available with this machine are according to the latest ISO
standards and adopted by the Industrial CNC controller manufacturers worldwide. Following
G, M, F, T, S commands are included in this controller.
Example 11:
Program by I, K parameter.
Raw material size or Stock size = Dia. 25mm X 80mm Length.
TOOL/STANDARD,15,55,0,10,3)
(COLOR,128,64,64)
(STOCK/80,25,0,0)
Page 145 of 234

//A=55: total angle between two side

edges,
//ITP=3:ITP is a value indicating the tip
position of the Imaginary Tool Point
with respect to the Tool Nose Radius
Center Point.
//Stock definition (L,D1,D2,Z),

//D2=0:Hole Dia.,
//Rod Dia.25 X 80 Length in mm.
//Circular interpolation (CW) program by G03 command with I, K Parameter.
N01 M03 S2000 (-Spindle Start Clockwise With Spindle

Speed 2000)
N02 G00 X25 Z2 (-Rapid Positioning Up to the Reference
Point)
N03 G01 X24 F80 (-Linear interpolation up to specified
point (X= 24) with feed 80mm/min)
N04 G01 Z-20 F60 (-Linear interpolation up to specified
point(X= 24,Z-20) with feed 60mm/min)
Page 146 of 234
N05 G01 X25 F80 (-Linear interpolation up to specified

point (X= 25) with feed 80mm/min)
N06 G01 Z0 F80 (-- Linear interpolation up to specified
point(Z= 20) with feed 80mm/min)
N06 G03 X24 Z-1 I1 K0 F80 (--Circular Interpolation Clockwise up to
point of arc along X-axis. K= 0 =
80mm/min)

(Z=0))

Page 147 of 234

80mm/min)

(Z=0))
80mm/min)
N20 G00 Z0 (-- Rapid Transverse up to reference
point(Z=0))
point of arc along Z-axis. Feed )
N26 G00 Z0 (--Rapid Transverse up to reference point
(Z=0))
point of arc along Z-axis Feed
Page 148 of 234

(Z=0))
point of arc along X-axis.K= 0 = Distance
between start point & center point of arc
along Z-axis feed rate 80mm/min)
point.(Z=0)
80mm/min)
N44 G00 Z0 (- Rapid Transverse up to reference point.
(Z=0))
point for start point of arc X=8, Z=0

80mm/min)
Page 149 of 234


(Z=0))
N54 G03 X24 Z-9 I9 K0 F80 (-- Circular Interpolation Clockwise up to
point of arc along X-Axis. K= 0 =
80mm/min)
(Z=0))
N60 G03 X24 Z-10 I10 K0 F80 (--Circular Interpolation Clockwise up
to End point of arc i.e. X=24,Z-10.& I =
center point of arc along X-axis. K= 0 =
80mm/min)
N62 G00 Z0 (-Rapid Transverse up to reference point
(Z=0))
to End point of arc i.e. X=24, Z-11. & I =
Page 150 of 234


80mm/min)
(Z=0))
to End point of arc i.e. X=24, Z-12.& I =
80mm/min)
N74 G00 X25 Z2 (-- Rapid Transverse up to reference
Point(X=25, Z=2))
N76 M30 (---------------Program End & Rewind)
final simulated program

Toolpath is shown in foolowing picture.
Page 151 of 234

13.1.5 G04 - PROGRAMMED DWELL
G04 Command will delay the execution of next block by given time.
Format: G04 X__
X specifies dwell in seconds.
This code is used mainly after the spindle ON command, as the spindle will require some time
to reach to the specified speed, before that the cutting operation should not start.
13.1.6 G20 - INCH PROGRAMMING
This is the modal command which commands the controller that the dimensions
specified in blocks following the current block is in the INCH system.
Format: G20
13.1.7 G21 - METRIC PROGRAMMING
This is the modal command which commands the controller that the dimensions specified
in blocks following the current block is in the METRIC system. i.e. in millimeter format. METRIC
format is the default format of dimensioning.
Format: G21
NOTE: The definition of dimensioning system is to be done only once in the part program in
first block. If it is specified more than one time the preprocessor will invoke the ERROR
ALARM showing that this is the violation of programming code. It is not possible to switch
from G20 to G21 in the program.
13.1.8 G28 - AUTO. RETURN TO REF. POINT
This command will move the tool to the specified reference point. In this command the tool
movement will be rapid.
Format : G28 X___ Z__
No Feedrate (F Word) is required to be programmed as it is taken from internally set values.
13.1.9 G70 - FINISHING CYCLE
After roughing operation this cycle is used to achieve the final dimensions.
Page 152 of 234

Finish allowance has to be kept before starting this cycle. The tool path is same as the
roughing operation.
Format: G70 P __ Q__
Here ,
P= starting block of the roughing cycle.
Q= end block of roughing cycle.
This cycle is normally used after G71,G72 & G73 codes.
13.1.10 G71 – STOCK REMOVAL IN TURNING
The G71 code commands a multiple repetitive cycle, sometimes referred to as a canned cycle.
Canned cycles are used within a CNC program to simplify programming, since only the
dimensions describing the required component profile are required. The CNC control will then
generate the roughing cuts needed to make this component profile, from within its own
memory.
Format : G71 U(d) R(e)
G71 P__ Q__ U(u) W(w) F__
Here,
U(d) = Depth of Cut ( For trainer machine it is 1mm).
R(e) = Escaping amount ( After depth of cut, this is the return path
for the tool in X + Direction)
P = Starting block no. of the program for the required shape
Q = Final block no. of the program for the required shape
U(u) = Finishing allowance in X direction.
W(w) = Finishing allowance in Z direction.
F = Feed-rate for cutting.
Page 153 of 234

Example 12 (G71): -
(COLOR,128,64,64)
(STOCK/80,25,0,0)
Point with respect to the Tool Nose Radius Center Point.
//Stock Definition (L,D1,D2,Z),

//D2=0:Hole Dia.,
Page 154 of 234

//STOCK REMOVAL CYCLE by G71 command.

N10 M03 S1800 (---- Spindle start clockwise with speed
2000.)
N20 G00 X30 Z5 (--- rapid positioning up to reference point
X=30, z=5)
N30 G71 U1.0 R0.5 (---stock removal operation with depth of

cut 1mm on dia.& escaping amount 0.5mm)
N40 G71 P50 Q120 U0.5 W0.5 F50 (stock removal operation for
turning, start
block no. for finish part p=50,end of block for finish part
Q=120.Finishing allowance along a x axis
0.5 & along z axis, feed rate 80mm/min.)
N50 X10 (---starting block for required shape with

G01 command. )
Page 155 of 234
N60 G01 Z-8 F80

N70 G01 X15 Z-12
N80 G01 Z-21
N90 G01 X23 Z-33

N100 G01 Z-38
N110 G01 X25 Z-40
N120 Z-25 (--- Ending block for required shape)

N130 G70 P50 Q120 F20 S2000 (---finishing cycle with start block
no.P=50,end Block no.=120 )
N140 G00 X30 Z5 (--Rapid positioning up to reference point
(Dia.)X=30,(length) z=5))
N150 M30 (--- Program end & rewind)
Page 156 of 234
Tool Path:
13.1.11 G72 – STOCK REMOVAL IN FACING
The G72 code commands a multiple repetitive cycle, sometimes referred to as a canned cycle.
The G72 cycle is similar to the G71 cycle except that the cut is applied in the Z axis.
Canned cycles are used within a CNC program to simplify programming, since only the
dimensions describing the required component profile are required. The CNC control will then
generate the roughing cuts needed to make this component profile, from within its own
memory.
Format: G72 W(d) R(e)
G72 P__ Q__ U(u) W(w) F__
Here ,
W (d) = Depth of Cut ( For trainer machine it is Max.1mm).
R (e) = Escaping amount ( After depth of cut, this is the return
Page 157 of 234

path for the tool in X + Direction)
Example 13:
(STOCK/80,25,0,0)
Point with respect to the Tool Nose Radius Center Point
Page 158 of 234


//D2=0:Hole Dia.,
N10 T1 (------ Tool no. 1, present tool)

N20 M03 S1800 (------ M03-spidle start clockwise with
speed 1800 rpm.)
N30 G00 X25 Z0 (--Rapid position up top reference point, X
as a Dia.Value = 25, Z = 0)
N40 G72 W0.5 R0.5 (-- stock removal operation for facing
with 0.5 mm depth of cut along Z axis(W)
& escaping amount(R) 0.5)
N50 G72 P60 Q140 U0.5. W0.0 F80(--stock removal operation for
facing with start block no.(P) for
finished part & end block no.(Q) for
finished part, with finishing allowances
along X axis (U=0.5)&along Z Axis (W=0)
N60 G00 Z-21 F100. (-- Start of block for required shape. )
Page 159 of 234
N70 G01 X25.

N80 Z-18 X22
N90 Z-18. X17.
N100 G02 Z-16 X13 R2.
N110 G01 Z-11
N120 G01 X10
N130 G01 Z-5.
N140 G03 Z0 X0 R5 (-- End of block for required shape.)
N150 G70 P60 Q140 F20 S2000 (---finishing cycle with start block
no.P=60,end block
no.Q=140, feed f=20mm/min,spindle speed 2000rpm. )
N160 G00 X33 (-- Rapid positioning up to reference point

along axis=33)
N170 G00 Z30. (-- Rapid positioning up to reference point
along Z axis=30)
// second operation is grooving

(TOOL/GROOVE, 0.2, 0.2, 30, 4,0.3 ,0.3 , 90, 0)
TOOL DEFINITION(R1,R2,L,W,A1,A2,OA,ITP)
//R1=0.2mm:corner radius.
//R2=0.2mm:corner radius.
//L=30mm:length of tool.
//W=4mm: Width of tool.
//A1=0.3: side angle.
//A2=0.3: side angle.
//OA= 90 Angle of tool
Point.
N200 T5 (-- Tool no.5, for Grooving operation. )
N210 G00 Z-14 (-- rapid positioning up to specified point
along Z axis.)
Page 160 of 234

N220 G00 X14 (-- rapid positioning up to specified point

along X axis.
N230 G01 X9 F11 (--linear interpolation along X axis As
diameter value with feed 11mm/min.)
N240 G00 X20 (--Rapid positioning along X axis)
N250 Z20 (--Rapid positioning along X axis)
N260 M30 (-- program End & rewind)
Tool Path:
13.1.12 G73 PATTERN REPEATING CYCLE:
This cycle allows cutting a fixed pattern repeatedly, with a pattern being
displaced bit by bit.
Format : G73 U(i) W(k) R(d)

G73 P__ Q__ U(u) W(w) F__
Where ,
U(i) = Distance of relief in X direction
W(k) = Distance of relief in Z direction
Page 161 of 234
R(d) = No. of divisions for the pattern.

Example 14:
Raw material Size or Stock size = Dia.25mm X 80mm Length.
SAMPLE PROGRAM:-
(STOCK/80,25,0,0)

//ITP=3:ITP is a value indicating the tip position of the Imaginary Tool Point with respect to the
Tool Nose Radius Center Point
Page 162 of 234


//D2=0:Hole Dia.,
N00 M03 S1800 (--Spindle start clockwise with spindle

speed 1800.)
N01 G00 X25 Z2 (-- rapid positioning up to reference point
X (as diameter)=25,Z=2)
Page 163 of 234

N02 G73 U5.0 W0.5 R10 (------Pattern Repeating Cycle with Relief
in 5 (X-Dir.) & 0.5 (Z-Dir.) with No. of
Division for pattern 10 (R))
N00 G73 P04 Q08 U0.5 W0.5 F60 (--Pattern Removal Operation with
Start of Block (P) =04& End of Block
(Q)=08 with Finishing Allowance 0.2mm
on each axis & Feed rate 60 mm/min)
N04 G00 X15.000 (--Starting block no. of the program for
the required shape)
N05 G01 Z-15.000
N06 G01 X22.000 Z-25.000
N07 G01 X25
N08 G00 Z0.000 (-- Final block no. of the program for the
required shape)
N11 G70 P04 Q08 (-- Finishing Cycle for the previously
Defined Block (P) =04 & (Q) 08)
N13 G00 X28 Z2 (-- Rapid Positioning Up to the Reference
Point (i.e. (Diameter) X=25, (Length) Z=2))
N14 M30 (--Program End & Rewind)
Page 164 of 234

TOOL PATH:-
13.1.13 G74-PECK DRILLING CYCLE
This cycle is designed for deep hole drilling .The drill entering the work piece by a
predetermined amount then backing off by another set amount to provide breaking &
allowing chips to clear the drill flutes.
Format : G74 R__

G74 X__ Z__ Q__ F__
Where,
X&Z = Final respective coordinates
Q = Depth of cut in mm.
R = Return amount in mm.
F = Feed in mm/min
Page 165 of 234

Example 15:
(COLOR,255,255,255)
//Tool Definition
//D=8mm:Diameter
//A=90 degree: angle
//L=50mm:Length of tool
(STOCK/80, 25, 0, 0)
//Stock Definition (L, D1, D2, Z),
//D2=0:Hole Dia.,
Page 166 of 234

//PECK DRILLING CYCLE(G74)
N001 M03 S1500 (--Spindle start clockwise with speed 1500.)

N002 G00 X0 Z0(Rapid positioning up reference point=0,Z=0.)
N002 G74 R2.0 (Drilling cycle with return amount 2mm.)
N003 G74 X0 Z-30 Q3.0 F20 (-- peck drilling cycle up to -30mm length
with depth of cut(each peck) 3.0mm & feed
20mm/min.)
N004 G00 Z5 (--Rapid positioning up 5mm along Z axis.)

N007 M30(--Program End & Rewind.)
Page 167 of 234

TOOL PATH:-
13.1.14 G75 (GROOVING CYCLE):
The G75 command permits drilling and grooving in the X axis. We can cut grooves on diameter
of work piece very easily with this command. The working of this cycle is very simple. First the
tool is brought to the initial position of the groove considering the width of the tool. The we
have to define the target points in X and Z axis , stepover in X axis and step over amount in Z
direction only. The movements of the tool to finish the grooving is decided by the control.
A G75 command is written in the following
Format :
G75 R (1)_ ;
G75 X (U)_ Z(W)_ P_ Q_ R(2)_ F_ ;
Where,
the definitions of R (1) , X (U) , Z (W) , P , Q , R (2) and F are the same as G74.
R(1) is the peck return amount.
X (U) is the diameter of the bore if step over is used (i.e., stepping along the X axis to repeat
the peck cycle).
Z (W) is the depth of the bore.
P is the step over in the X axis measured in micron's (without sign).
Q is the pecking depth in the Z axis measured in micron's (without sign).
R (2) is the retract move at the base of the groove.
F is the feedrate.
Page 168 of 234

Example 16 (Grooving Cycle):
Raw material size or stock size is :- Dia.25mm X 50mm length.
(TOOL/GROOVE,0.2,0.2,15,3,3,3,90,0)
(COLOR,255,255,255)
//Tool Definition
//R1&R2 = 0.2mm radius of tool
//A1&A2 =3 degree: angle of tool
// W= 3mm Width Of tool
//L=15 mm: Length of tool
// OA= 90 degrees Angle of Tool
(STOCK/80,25,0,0)
//D2=0:Hole Dia.,
Page 169 of 234
(TOOL/GROOVE, 0.2, 0.2, 15, 3, 3, 3, 90, 0)

(COLOR, 255,255,255)
N10 S2000 M03
G00 X26 Z2
N20 G0 Z-23.0
(STOCK/60,25,0,0)
N30 X28.0
N40 G75 R1.0
N50 G75 X18.0 Z-30.0 P750 Q2000 F0.15
N60 G00 Z5.0
N70 M30
Page 170 of 234

13.1.15 G76- TAPER THREADING CYCLE
This cycle is designed for Taper Threading Cycle. This canned cycle is suitable for Taper thread
cutting operation.
Format : G76 Paabbcc Q__ R__

G76 X__ Z__ R __ P__ Q__ F__
Where,
First block:
G76 P aabbcc Q__ R__
P is a six digit Data Entry in three pairs
aa digit - No. of finishing cut (01-99)
bb No. of Leads for gradual pull out(0.0 -9.9 times lead)(00-99)
cc angle of thread(00,29,30,60,80 only).
Q minimum cutting depth in micron.
R Fixed amount for finish allowance (Decimal point not allowed).
Second Block:
G76 X__ Z__ R__ P__ Q__ F__
X Minor Dia. of thread(absolute).
d (Depth).
X (minor Dia) in mm=major Dia-2*d .
Z End of thread along z-axis in mm.
R Radial difference between start and End Point. (For taper threading)
P Height of thread (d)(one side depth in microns).=500micron
Q Depth of first Thread in microns.= 25micron.
F Pitch of thread.
Example 17 (Strait thread):
// program for G76 strait thread.

(STOCK/45,25,0,0)
(TOOL/STANDARD, 15, 45, 0, 10, 3)
Page 171 of 234
// Tool Definition (BA, A, R, IC, ITP)

(STOCK/80, 25, 0, 0)
//D2=0:Hole Dia.,
N0 T1
N1 M03 S2000
N2 G00 X25 Z0
N3 G90 X24.0 Z-30 F70
N4 G90 X23.0 Z-30 F70

N5 G90 X22.0 Z-30 F70
N6 G90 X21.0 Z-30 F70
N7 G90 X20.0 Z-30 F70
N8 G90 X19.0 Z-30 F70
N9 G90 X18.0 Z-30 F20
N17 M05
Page 172 of 234

(TOOL/THREAD, 55, 40, 8, 90)

//threading tool definition (A, L, W, OA)
//OA= tool angle
N18 T5
N19 M03 S800
N20 G01 X19
N21 G01 Z2
N22 G76 P001255 Q50 R25
N23 G76 X16.36 Z-15 P819 Q25 F1
N24 G00 X25 Z10

N25 M30
Simulation for above example is shown below:-
Page 173 of 234

Tool Path:-
Example 18 (G76 Cycle):

Raw material size or Stock size:- Dia.25 X 80mm Length.
// program for G76 threading cycle (Taper thread.)

(STOCK/80,25,0,0)
Page 174 of 234


//D2=0:Hole Dia.,
//Z=0:Zposition of program origin relative to stock origin.)
N1 M03 S3000 (----Spindle Start Clockwise With

Spindle Speed 3000)
N2 G00 X25 Z0 (---- Rapid Positioning up to Reference
point)
N3 G90 X24.0 Z-30 F70 (-- Diameter Cutting Cycle with 1mm (X)
cut up to -30 Length (Z) With Feed F= 70
mm/min)
mm/min)
mm/min)
mm/min)
mm/min)
Page 175 of 234

mm/min)
mm/min)
cut up to -30 length (Z) With Feed F= 70
mm/min)
N11 G01 X18 Z0 (----------- Linear Interpolation)
cut up To25 length (Z) with radially0.25
(R) With Feed F=70 mm/min)
cut up to –25length (Z) With redially0.25
(R) With Feed F= 70 mm/min)
cut up to length (Z) With redially0.25 (R)
With Feed F= 70 mm/min.)
Page 176 of 234

cut up to -25 length (Z) With
redially0.25 (R) With Feed F= 70
mm/min).
N16 G00 X35 Z20 (---- Rapid Positioning up to Reference
point)
N17 M05 (-------Spindle stop)
(TOOL/THREAD, 40, 25, 10, 90)

//threading tool definition (A, L, W, OA)
//OA= tool angle
N18 T5 (--Tool change new tool no 5)
N19 M03 S500 (--Spindle Start Clockwise With Spindle
Speed 800)
N20 G01 X19 (-- Linear Interpolation)
N21 G01 Z2 (-- Linear Interpolation)
N22 G76 P000055 Q50 R5

N23 G76 X17 Z-25 R-1.0 P500 Q25 F1 (---Taper threading with 1 mm
pitch)
N24 G00 X25 Z10 (--- Rapid Positioning up to Reference
point)
N25 M30 (--Program End & Rewind)
Page 177 of 234

Simulation for above example is shown below:
Tool path:-
13.1.16 G90 –DIAMETER CUTTING CYCLE
This cycle is used to reduce the diameter of the job. In this cycle the tool will be back to the
starting position after cutting the diameter. In this machine the depth of cut is 1mm. So if you
want to reduce the diameter of the job from 22mm to 18 mm you will have to use 4 G90
codes.
Format : G90 X___ Z___ F__
Where,
F = Feed in mm/min
Page 178 of 234

Example 19:
(STOCK/80,25,0,0)
//A=45: total angle Between two side edges,
//Stock Definition(L,D1,D2,Z),
//D2=0:Hole Dia.,
N001 M03 S2000 (--Spindle Start Clockwise With Spindle

Speed 2000)
N002 T01 (---Tool No.1 Present for Cutting
Operation)
N05 G00 X25 Z2 (------- Rapid Positioning up to Reference
point (i.e. X=22 ,Z=2))
Page 179 of 234

N07 G90 X24 Z-35 F80 (--Diameter Cutting Cycle with 1mm (X)
mm/min.)
mm/min.)
mm/min.)
N010 G90 X21 Z-35 F80 (--Diameter Cutting Cycle with 1mm (X) cut
up to -20 length (Z) With Feed F= 80
mm/min.)
N015 G90 X20 Z-35 F80 (-- Diameter Cutting Cycle with 1mm cut up
to -20 length with Feed F= 80 mm/min.)
to -20 length With Feed F= 80 mm/min.)
Page 180 of 234

to -20 length With Feed F= 80 mm/min)
N060 G00 X22 Z2 (--Rapid Positioning up to Reference Point
(i.e. X=22, Z=2))
N060 M30 (-- Program End & Rewind)
Page 181 of 234

TOOL PATH:
13.1.17 G92 -THREAD CUTTING CANNED CYCLE
This canned cycle is suitable for External thread cutting operation. This cycle is same to that of
G32 except that in G92 the tool is returned to the starting position.
Format : G92 X___ Z___ F__
Where,
X = Threading diameter.
Z = Thread length.
F = Thread Pitch.
NOTE:
While the execution of thread cutting cycle, Spindle Speed is nonprogrammable, Controller
will automatically adjust it to proper value and after completing the threading operation the
original Spindle Speed will be restored.
According to the pitch the total depth has to be decided & that many times G92 has to be
called. For threading operation the depth of cut is less which can be 0.1 mm. So if the pitch is 1
mm then there should be 8 to 9 G92 calls.
Example 20:
Page 182 of 234

(TOOL/THREAD, 55, 40, 5, 90)

(STOCK/80, 22, 0, 0)
//D2=0:Hole Dia.,
Threading tool definition (A,L,W,OA)

//w= width of tool.
//OA= tool angle
//THREADING CANNED CYCLE BY G92.
N13 M03 S500 (-- Spindle Start Clockwise With Spindle

Speed 500)
N14 G00 X22 Z2 (-- Rapid Positioning up to Reference point
(i.e. X=22, Z=2))
N15 G92 X21.9 Z-10 F1 (-- Thread Cutting Cycle with 0.1mm (X)
mm/min.)
N16 G92 X21.8 Z-10 F1 (------- Thread Cutting Cycle with 0.1mm (X)
cut up to –10 length (Z) With Feed F= 1
mm/min.)
N17 G92 X21.7 Z-10 F1 (------- Thread Cutting Cycle with 0.1mm (X)
cut up to – 10 length (Z) With Feed F= 1
mm/min.)
N18 G92 X21.6 Z-10 F1 (-------- Thread Cutting Cycle with 0.1mm (X)
mm/min.)
N19 G92 X21.5 Z-10 F1 ( Thread Cutting Cycle with 0.1mm (X) cut
up to -10 mm)
N20 G92 X21.4 Z-10 F1 ( Thread Cutting Cycle with 0.1mm(X)cut
up to -10mm Feed F= 1 mm/min.)
N21 G92 X21.3 Z-10 F1 ( Thread Cutting Cycle with 0.1mm (X) cut
up to -10 mm F= 1 mm/min.)
N22 G92 X21.2 Z-10 F1 (---------- Thread Cutting Cycle with 0.1mm
(X) cut up to -10 length (Z) With Feed F=
1 mm/min).
Page 183 of 234

N23 G92 X21.1 Z-10 F1 (--------- Thread Cutting Cycle with 0.1mm
(X) cut Up to -10 length (Z) With Feed F=
1 mm/min.)
1 mm/min.)
N25 G92 X20.9 Z-10 F1 (-------- Thread Cutting Cycle with 0.1mm (X)
mm/min.)
1 mm/min.)
N27 G92 X20.7 Z-10 F1 (--------- Thread Cutting Cycle with 0.1mm
1 mm/min.)
N30 G00 X24 Z20 (---Rapid Positioning up to Reference point
(i.e. X=24, Z=2))
N35 M30 (--------------------Program End & Rewind)
Tool path:-
Page 184 of 234

13.11.18 G94 CANNED CYCLE FOR FACING
This cycle is used for facing of the job. In this cycle the tool will be back to the starting
position after finishing of one cut on face. The same cycle can be used to cut taper with help
of R parameter.
Format : G94 X__ Z__ R__F__
Where,
R = Taper value (big dia – small dia/2) with sign
F = Feed in mm/min.
Example 21:
(TOOL/STANDARD, 15, 40, 0, 10, 3)
//R= 0: Tool Nose radius.
//I.C.=10:Inside circle,
(STOCK/50, 25, 0,-3)
//D2=0:Hole Dia.,
Page 185 of 234
(TOOL/STANDARD, 15, 40, 0, 10, 3)

(COLOR, 255,255,255)
M03 S2000
G00 X25 Z3
(STOCK/50,25,0,-3)
G94 X-1.0 Z2.5 F40
G94 X-1.0 Z2.0 F40
G94 X-1.0 Z1.5 F40
G94 X-1.0 Z1.0 F40
G94 X-1.0 Z0.5 F40
G94 X-1.0 Z0.0 F40
G00 Z10.0
M30
Simulation is shown step by step.
Example 22 (G94 CANNED CYCLE FOR FACING WITH TAPER):
//R= 0: Tool Nose radius.
//I.C.=10:Inside circle,
Point with respect to the Tool Nose
Radius Center Point
(STOCK/50, 25, 0,-3)

Page 186 of 234

//D2=0:Hole Dia.,
//Rod Dia.25 X 50 Length in mm

(COLOR,255,255,255)
(STOCK/50, 25, 0, 0)
N10 M03 S2200
N20 G00 X28.0 Z5.0
N30 G94 X15.0 Z4.0 R-2.0 F50
N40 G94 X15.0 Z3.0 R-2.0 F50

N50 G94 X15.0 Z2.0 R-2.0 F50
N60 G94 X15.0 Z1.0 R-2.0 F50

N70 G94 X15.0 Z0.0 R-2.0 F50
N80 G94 X15.0 Z-1.0 R-2.0 F50
Page 187 of 234

N90 G94 X15.0 Z-2.0 R-2.0 F50

N100 G94 X15.0 Z-3.0 R-2.0 F50
N110 G94 X15.0 Z-4.0 R-2.0 F50
N120 G94 X15.0 Z-5.0 R-2.0 F50
N130 G94 X15.0 Z-6.0 R-2.0 F50
N140 G94 X15.0 Z-7.0 R-2.0 F50
N150 G94 X15.0 Z-8.0 R-2.0 F50
N160 G94 X15.0 Z-9.0 R-2.0 F50
N170 G94 X15.0 Z-10.0 R-2.0 F50
N180 G00 Z25.0
N190 X50.0
N200 M30
Simulation of above program is shown below.
TOOL MOVEMENT IS SHOWN FOR TAPER FACING OPERATION.:
Page 188 of 234

13.1.19 G96 - CONSTANT SURFACE SPEED ON
G97 - CONSTANT SURFACE SPEED OFF_

G96 (Constant Surface Speed Control):
If surface speed (relative speed between tool and billet) is set after the address S __ , the
spindle speed is calculated so that the surface speed is always the specified value in relation
to the tool position. Spindle speed is calculated by the control by the following formula
The units used will depend on whether the machine is operating using metric or imperial
measurements.
Spindle speed is calculated by the control by the following formula (For Metric Units):
Cutting Speed (C.S.) = 3.14 x D x N / 1000
Where, D = diameter of Job in mm N= Spindle Speed in rpm C.S. is in m/min
Page 189 of 234

The units of surface speed are as follows:
Input Unit. Surface Speed Unit
Metric - Millimeter. Meters per Minute, M/Min.
Imperial - Inches Feet per Minute, Feet/Min
A G96 command for surface speed control is written in the following format:
G96 S __;Where,
S _ is the surface speed (M/Min or Feet/Min)
G97 (Spindle Speed in Rev/Minute):
The G97 command allows a spindle speed written in the units, revs per minute, to be entered
into the machine controller. All subsequent spindle speeds are defined in revs per minute,
after the original read-in of the command G97. If a change of spindle speed is required within a
program, only the S __ value needs to be entered.
A G97 command for spindle speed control is written in the following format:
G97 S __;
Where, S __ is the spindle speed, written in the format revs per minute.
Example 23:
(TOOL/STANDARD, 40, 40, 0, 10, 3)

(COLOR, 255,255,255)
(STOCK/30, 22, 0, 0)
M03 S2000 (--------------- Spindle Start Clockwise With
Spindle Speed 500)
N000 G00 X22 Z0 (------- Rapid Positioning up to Reference
point (I.e. X=22, Z=0)
N001 G96 S100 (------Constant Surface Speed ON with
cutting Speed 100m/min)
N002 G04 X10 (----------- Dwell For 10 Second)
N003 G01 X0 F80 (--------Linear Interpolation with feed rate
80mm/min.)
N004 G01 X22 ( Linear Interpolation up to specified
point with feed rate 80mm/min.)
N006 G97 (------------------- Constant Surface Speed
OFF)
N007 M30 (-------------------Program End & Rewind)
Page 190 of 234

Page 191 of 234

14.0 Description of M Codes
14.1 M00 – PROGRAM HAULT
This command is useful to check the job in between the program. With this command
the axis & the spindle will be stopped. After checking the job parameters rest program will be
executed by pressing the ENTER key. The spindle will be automatically started with the
previous speed.
Format: M00
14.2 M01 - OPTIONAL PROGRAM STOP
The M01 is used to STOP the Operation in Auto Mode. This code is only effective when the
Optional Stop is enabled. This can be set from Setup menu.
Format: M01
In this case auto. Mode Operation will be stopped. User can continue the Operation after
pressing the <Enter> Key.
14.3 M02 - PROGRAM END
The M02 is used to END the Operation in Auto. Mode. After a block specifying the end of
program is executed, control returns to the start of program.
Format: M02
14.4 M03 - SPINDLE ON CLOCKWISE
This command is used to start the Spindle in Clockwise Direction. Spindle speed can be
specified with this command as follows,
Format: M03 S__
In this case spindle will start rotating in Clockwise direction with S speed in rpm. Speed of
rotation is specified in S word (i.e. S600). But S word is not mandatory. If not specified, default
maximum speed set internally is used for operation.
14.5 M04 - SPINDLE ON ANTICLOCKWISE
This command is used to start the Spindle in anticlockwise Direction.
Format: M04 S__
In this case spindle will start rotating in anticlockwise direction with the
Page 192 of 234
S speed...
14.6 M05 - SPINDLE STOP
This command is used to STOP the Spindle rotation.
Format: M05
Spindle rotation can also be stopped by M30 command.
14.7 M07 - COOLANT NO. 1 ON
This command is used to ON the Coolant Pump provided. If two pumps are provided, M07
command will start the Pump No. 1.
Format: M07
14.8 M08 - COOLANT NO. 2 ON
This command is used to ON the Coolant Pump provided. If two pumps are provided, M08
command will start the Pump No. 2.
Format: M08
14.9 M09 - COOLANT PUMPS OFF
This command is used to STOP the Coolant Pumps. If both pumps are ON, M09 command will
STOP both the Pumps.
Format: M09
Coolant Pumps can also be stopped by M30 command.
14.10 M13 – SPINDLE CLOCKWISE & COOLANT ON
This command is used to move the spindle in clockwise direction & coolant ON.
Format: M13 S__
S = spindle speed in rpm.
14.11 M14 – SPINDLE ANTICLOCKWISE & COOLANT ON
This command is used to move the spindle in anticlockwise direction & coolant ON.
Format: M14 S__
S = spindle speed in rpm.
Page 193 of 234

14.12 M30 - END OF PROGRAM
M30 command must be the last command in the program. This command indicates the END
OF PROGRAM. If not specified, ERROR ALARM will be displayed. The M30 command will stop
all the Auxiliary functions like, Spindle & Coolant. After the execution of this command
program will be reset to first Block
18.13 M98 – SUBROUTINE CALL
M99 - END OF SUBROUTINE
When a program contains certain fixed sequences or frequently repeated patterns, these
sequences or patterns may be entered into memory as a subprogram to simplify
programming. A subprogram can call another subprogram .When the main program call a
subprogram; it is regarded as a one-loop subprogram call.
When a command calling a subprogram is encountered in the main program control is passed
to the subprogram. And control returns to the main program when returning command is
encountered in the program.
Format: M98 P__ L__
M99
Where,
P = subroutine repetitions.
L = subroutine label (alphabetical as well as numerical).
Page 194 of 234

15.0 DOs and DONTs
Sr. No. Do
1. Check the earthling once in a week. Earth to Natural Voltage should be 3
Volts maximum.
2. Please clamp the Job with proper care.
3. Manually rotate the spindle & check the obstruction. If there is obstruction do
not start the machine.
4. Before starting the machine please remove the burr & dust with clean Brush.
5. Release the Emergency stop of the machine.
6. Check oil level in tank once in a week.
7. Check the cutting edge of the tool before start.
8. Put the computer ON & Load the software program.
9. Before cutting the material please do dry run in air. If dry run is OK then start
the machine.
10. While stopping the machine please check that tool is away from the job &
tool removal is easily possible.
Sr. No. Do Not

1. Do not start the machine on Load or in cutting position.
2. Do not start the machine without solid state stabilizer.
3. Ambient temperature should not be above 350C.
4. Do not spray water or don’t clean the controller with wet cloth for critical
control part. Electronic IC will be defected in Humid atmosphere.
5. Do not stop MACHINE on LOAD.
6. Do not start the machine when there is power fluctuation more than ± 10 %
7. Do not use the PC for any other purpose.
8. Do not leave the machine unattended.
9. Do not Tamper the CONTROLLER.
10. Do not change PC settings.
Page 195 of 234

16.0 CNC Lathe Maintenance
The CNC Lathe machine is a very delicate machine. It is the combination of Electronic,
Electrical & Mechanical parts. A lot of attention is required to keep the machine in working
condition. Following are the points which have to be checked.
16.1 Controller related:
The Electronic controller of the CNC machine works on Single phase supply (230 V AC 25 V).
It contains various parts such as Computer, PLC, Servo motor drives, and Power supply.
Stabilizer etc. The points given below will take care of the controller.
1. Keep mains s/w off when machine is not in use.

2. Rout supply cable in a proper way so that it should not be bending, twisted or
damaged.
3. Check Earthing connected to the controller & the CNC machine. Proper earthing is
nothing but the potential difference between neutral to earth of the mains
supply. This difference should not be more than 2 volts. If it is more than that the
controller will malfunction & also it can be highly dangerous. If the earthing is not
proper please consult your Electrical department & get it done. Earthing
requirements and procedure is mentioned in the later part of the manual.
4. Always check your program with simulation before actual machining.
5. Check the level of humidity that should not be more than 70%.
6. There should not be any high current load (such as welding etc.) on the same
phase connected to the CNC machine. That can create fluctuations in the supply.
7. Take care of the cables connected between the controller & the Lathe machine.
Do not put any weight on it.
8. Do not try to change any wire or check anything inside the controller unless &
until you contact Hytech Support Division.
16.2 Lathe related :
The Lathe machine has various mechanical assemblies such as ball-screw, Spindle etc.
Please take care of these precision parts so that it should not be damaged.
1. Keep the machine clean. Remove the chips of the job.

2. Do not keep unnecessary things near the machine.
3. Use the machine for soft materials only( such as Aluminum, Brass, Copper etc.).
4. Before machining always check that the job is clamped properly & the tool is away
from the job (i.e. the tool should be in positive direction of Z axis.)
5. Please keep the depth of cut of 1 mm max.
6. Before machining check whether the tool is properly clamped.
Page 196 of 234

7. Use proper feed & Speed values in the program. Keep the federate at a low value
to get a good finish.
8. Check Lubrication oil level once in a week
9. Always do the oiling first before actual working on the machine.
10. While actual machining if you find any problem use Emergency stop button on the
controller (Red colored) to avoid any accidents.
11. MS parts can be machines on Hytech trainer lather machine but user has to use
ample amount of coolant during the cutting of harder materials.
12. User has to make sure that there is no coolant left on the guideways or the
machine tray. Coolant is highly corrosive and its residues might end up damaging
the metal components of the machine.
16.3 Electrical Maintenance
The CNC Machine with Stepper Motor requires 230vac 25 V at 50Hz input supply which is
achieved through 15 AMP socket supplied by the Electrical board. CNC Machine with Servo
motorsrequires Three Phase power supply (415V, +-2% 50 Cycles, 3 Phase). Total load on
stepper motor based machine is around 6 KVA and that on the servo motor based machine is
around 7 KVA.
1. A 3 KVA stabilizer is provided with the machine for various electronic
parts. So even if the incoming supply is varied from 170 to 260 Volts,
stabilizer will provide a continues 230 V supply with 4% regulation. But
see that the supply for the machine is not varying much.
2. As stated earlier machine proper earthing .You have to measure it once
in a week. It should be located near machine & connected to machine
with continuous copper wire of 3 mm².
3. There should be a gap between the controller and the walls to provide
necessary ventilation to the controller.
4. Before disconnecting any wire, switch off controller & remove the
power plug from mains input.
5. There are various MCBs provided inside the controller. their rating &
connection details are given below
A. 16 Amps. 2 Pole: For total supply of the CNC machine.
In case of any problem these MCBs can be tripped & provide
protection for the circuits.
6. Various fuses are provided for various Electronic circuits. Their details are
given below
A. Power supply unit: 2 Amp. for 24V DC (PLC)
7. For any Electrical fault, wiring diagram is provided along with this
manual.
Page 197 of 234

16.4 Conditional Checks:
Various check points are given below for various problems
16.4.1 Stabilizer
If it is tripped following problems will occur

1. Any motor will not work
2. Only PC will work
Check Points:
1. Check fuse
2. Press the trip button
3. Check input voltage. If it is below 170 V or above 260 V, the stabilizer
will remain tripped.
4. If the problem persists contact Hytech.
16.4.2 Power supply
The power supply contains +24 V, +36 V, +60 V supply.

1. If 24 V fails PLC, Spindle, Turret, Coolant & lubrication motor will not
work. X & Z axis motors will work. Check the fuse (2 Amp)
2. If 36 V fails X axis motors will not work.
3. If 60 V fails Z axis motors will not work.
4. Check whether MCB is tripped.
16.4.3 VFD
VFD is nothing but a variable frequency drive to control the spindle RPM. It is also called as AC
motor drive.
If the spindle is not rotating
1. Check the MCB (10 Amp) inside the controller, that can be tripped.
2. Check for the loose connections at the drive.
16.5 General Issues:
a) Tube light
If the tube light provided on the Lathe machine is not working
Check: -
1. Check the starter on the machine
2. Check mains MCB 2pole 16amp inside the controller.
Page 198 of 234

b)The Controller is not getting ON

1.Mains supply
2. Mains key lock switch on the front panel on the machine.
3. Main MCM (16amp 2pole) inside the controller.
c) Computer is not working

1.Input supply connecter
2. Mains cable connected to the computer at the back side.
3. The key lock switch
d) CNC is not getting ON

1. The MACHINE ON switch on the front panel of the controller.
2. Emergency stop button is pressed. If it is pressed release it.
3. Stabilizer is tripped or not.
e) Lubrication or Coolant motor not working

1. Mains supply.
2. Military connector on the controller for loose connection.
3. Coolant or Lubrication relay in the controller.
4.Input signal from PLC.
16.6 Earthing Requirements of Hytech CNC Machines with Servo Motors
1. 16 Amp - 3 Phase Power Point with Double Pole switch , 3 Phase Indication should
be provided with Bulb Indication.
2. Please provide 3 Phase MCB with 16 A capacity so that any overload or short circuit
will cut off electrical supply.
3. Please Provide Single Phase Preventer and 3 Lamp Indication for all 3 Phases (One for
Each Phase), Also, provide MCB of 16A for each phase.
4. 15 Amp Electrical Power point 230v -50 Hz with built in Fuse (15A 3pin socket with
Fuse)
5. The distance between Electrical Connection / supply and machine should not be more
than 2 meter.
6. The minimum Load Bearing capacity of the floor should be 2,000 Kg/Sq.m. in case of
CNC Lathe machine and 2,300 Kg/Sq.m. in case of CNC Milling Machine.
7. Material used for earthing should be of a reputed brand (Preferably with ISI Mark).
8. Maximum temperature of the room should not exceed 30°C.. Acceptable Dust Content
in air for CNC Machine is 20 mg / M3. Proper circulation of air should be maintained.
9. Provide 400 Lux Illumination for Lighting all over Lab. i.e. 40 Watts – 2 Tubelight per
100 sq. feet area
Page 199 of 234

10. Phase Voltage variation in each phase of 3 Phase Line should not be more than 10 Volt
for Base Voltage. For Average Voltage of 415 Volt; R, Y, B Phases should be within 410
to 420 Volts. Phase Balancing is important.
16.7 Necessary Earthing Arrangements for Servo motor based machine:
1. Earthing of the machine should be done as per IS 3043 : 1387 i.e. Code practice of
earthing. Use Charcoal– 100 Kg & Salt– 100 Kg minimum.
(Refer Diagram Below)
2. Earth to Neutral potential difference should be 2 volts maximum. If Earth resistance is

not within limit, Copper plate should be inserted as shown above.
3. Digital Control Units work on 5 Volts D. C. Any inductive load / noise due to inefficient
earthing might end up damaging these delicate units.
4. Resistance to Earth:The resistance between the main earth terminal and any Metallic
part of the machine should not exceed 0.1 Ohm.
5. Insulation resistance test: The insulation resistance measured with DC Voltage of 230
Volts between each conductor of the main circuit & earthed Frame should not be less
than 1 Mega ohm.
Please refer Indian Standard IS 3044-1987 Code of Practice for Earthing. All Earthing work
should be done by professional person.
16.8 Earthing Requirements of Hytech CNC Machines with Stepper Motors
1. Earthing of the machine should be done as per IS 3043 : 1387 i.e. Code practice of
earthing. Use Charcoal– 100 Kg & Salt– 100 Kg minimum.
(Refer Diagram Below)
Page 200 of 234

2. Earth to Neutral potential difference should be 2 volts maximum. If Earth resistance is

not within limit, Copper plate should be inserted as shown above.
3. Digital Control Units work on 5 Volts D. C. Any inductive load / noise due to inefficient
earthing might end up damaging these delicate units.
4. Resistance to Earth:The resistance between the main earth terminal and any Metallic
part of the machine should not exceed 0.1 Ohm.
5. Insulation resistance test: The insulation resistance measured with DC Voltage of 230
Volts between each conductor of the main circuit & earthed Frame should not be less
than 1 Mega ohm.
Please refer Indian Standard IS 3044-1987 Code of Practice for Earthing. All Earthing work
should be done by professional person.
Page 201 of 234

17.0 I/O Lines for CLT 100
INPUT COMMENT OUTPUT COMMENT

X0 XEncA Y0 X Pulse
X1 X+LimitSW Y1 X Direction
X2 X-LimitSW Y2 Z Pulse
X3 Z+LimitSW Y3 Z Direction
X4 Z-LimitSW Y4 Turret ON
X5 ThrPulse Y5 Lub
X6 TurretHomeSensor Y6 CNC ON
X7 EachToolSensor Y7 Coolent ON
X8 EMERGENCY STOP Y8 SpdFwd
X12 XRefHomesensor Y9 Sp. Rev
X13 ZRefHomesensor Y10 LED AUTO
X14 mopcystop Y11 LED CYCLESTART
X15 sp ccw Y12 led sp cw
X16 MCPTool clamp Y13 limitswon
X17 sp stop Y15 LEDCYCLESTOP
X18 mcp reset Y16 LED AUTO
X19 mopjog pb Y17 LED_CCW
X20 MOP cycle stat Y18 LED_CW
X21 pb auto Y19 LEDSPSTOP
X23 mop turret home Y21 LED JOG
X24 mcp jog z- Y22 LEDX-
X25 mop sp start Y23 LED_COOLENT
X26 jog x- Y24 LEDZ+
X27 mop ref pt Y25 LED_RAPID
X28 MCP_LUB Y26 LEDZ-
X29 MCPCNC ON Y27 LED_LUB
X30 MCP_RAPID ON Y29 LED_MC_ON
X31 MOP_TURRETEACHTO Y31 LED_RAPID
X32 Caxis JOGY- Y32 LED REF POINT
X33 MOP_COOLENTON Y33 LED_ESTOP
X34 MCP_Jog X+
X35 MOPJOGz+
X36 MCP_Jog X-
X37 MOPREF POINT
X38 MCP_Lub
X39 MOPCNC ON
X40 MCP_RapidON
X41 MOP Turret Index
X43 COOLENT ON
X44 MOP JOG X+
X45 mopJOG Z+
X46 ToolclampCcont
Page 202 of 234

18.0 GLOSSARY OF TERMS
Absolute Coordinate System
All coordinates are measured from a fixed data or zero point for each axis.
Absolute Data input
All programmed geometric data are related to a fixed zero point for each axis.
Absolute Measuring System
A measuring system in which all positions of an axis are measured from a fixed zero point. For absolute
measuring the following measuring devices can be used : Access Time
The time interval between the time at which data are called for from a storage device and the time delivery is
completed .
Accuracy
1. The degree of freedom from error: that is, the degree of conformity to truth or to a rule.
2. The difference between the target and the average from that target plus or minus three standard deviations
for a confidence limit of 99.9 percent. The averages and deviations are found by making many identical
Programmed moves and then correlating them. See also repeatability.
Active Memory
The part of the control logic in which data are stored as they are being executed.
Actual Position
The actual positional value of an axis feedback by the measuring system to the controller.
Adaptive Control (A/C)
1. A control method using sensors for real time measurement of process variables with calculation and
adjustment of control parameters as a
means of achieving near optimum process performance
2. Machine control units for which fixed speeds and feeds are not programmed. The control unit, working from
feedback sensors, is able to
optimize situations by automatically controlling these operating parameters.
Address
A coded identification, as represented by a name, label, or number for a register, location in storage, or any other
data source to indicate the destination of data, such as the location of a station in a communication network.
Address Format
The assignment of data contained on a tape to the different commands and functions of the machine. The five
types of address formats are word address, TAB sequential, fixed sequential, TAB ignore, are variable block
format.
Algorithm
A prescribed set of well-defined rules or procedures for the solution of a problem in a finite number of steps.
Alphanumeric
Referring to the totality of characters that are either alphabetic or numeric.
Amplifier
Page 203 of 234
A device for amplifying the output of an electrical signal. In a numerical control this is normally a servo system
which amplified the error signal of a measuring system.
Analog
1. Pertaining to representation by means of continuously variable physical quantities
2. Using physical variables such as distance or rotation to represent and correspond to numerical variables that
occur in a computation.
3. A system which utilizes electrical voltages or ratios to represent physical axis positions.
Analog-to-Digital (A?D) Converter
A device which converts an analog input signal to a digital output signal.
ASCII
American Standard Code for information interchange. A data transmission code which was standardized by the
American Standards Association. Seven bits are used to represent a character, with the eighth bit providing for
an even number of punched holes per character parity check.
Assembler
1. A translation program which converts program code written in assembler to machine code .
2. A machine-specific, low level programming language. The commands for the machine are written in a
mnemonic code which the computer can identify by a specific bit-pattern.
Asynchronous Axes
The control of these axes is independent of that of the main axes. For example, they might be auxiliary axes of a
handling robot fitted to an NC machine.
Automatic Guided Vehicle (AGV)
Computer-controlled vehicle which needs no rails, and which is used for the transportation of piece parts (and
cutting tools in some installation) in flexible manufacturing systems. It is usually guided by a single from an
inductive wire buried in the shop floor.
Automation
The use of machines for the performance of repetitive tasks. The jobs can be physical or mental work, and often
have to be carried out in sympathy with other equipment. Automated operations are often controlled by a
program which automatically checks the sequence Validity and corrects deviations.
Auxiliary Functions (M)
All functions which are programmed under the M-address (miscellaneous functions).
Axis
1. One of the reference lines of a coordinate system.
2. One of the lines of motion on a machine
3. A coordinate reference on a graphical device.
4. A general direction along which the relative movements of the tool and
work piece occur.
Axis Calibration
Some CNC systems offer an axis calibration feature which permits the compensation of systematic measuring
errors of axes, and thereby increases axis accuracy. For each axis, error values are stored, which are then added
to, or subtracted from, the measured value, depending on the position and orientation of the axis.
Page 204 of 234
Axis Control
A numerically controlled machine axis which is permanently connected to the control unit is designated an NC
axis. If the control unit is only temporarily or intermittently switched to an axis, this is referred to as a “half
numerically controlled axis” or 1/2 axis. A numerical control which controls two axes in an alternating fashion is
designated 2 x 1/2 axis. The simultaneous control of two axes with an additional axis switched on temporarily is
referred to as a 2 1/2 axes system.
Axis Lag
The dynamic difference between the calculated position target value and the actual position value of a machine
axis during feed or rapid traverse. At high speeds, axis lag can cause geometric errors in the contour of the
component.
Accuracy
Measured by the difference between the actual position of the machine slide and position demanded.
ANSI
Abbreviation for American National Standards Institute. It sets drafting standards.
Arc Clockwise
An arc generated by the tool motion of two axes in which path of the tool with respect to the work piece is a
clockwise when viewing the plane of motion from
the positive direction of the perpendicular axis.
Arc Counterclockwise
An arc generated by the tool motion of two axes, in which path of the tool with respect to the work piece is
counterclockwise, when viewing the plane of motion from the positive direction of the perpendicular axis.
Array
A rectangular or circular pattern.
Attribute
Textual information associated with CAD geometry. Attributes can be assigned to drawing objects and extracted
from the drawing database. Applications include creating bills of material.
Backlash
Movement between interacting mechanical parts resulting from looseness and deflections.
Backlash Compensation
Electronic compensation of backlash in the mechanical drive train of an axis feed.
Ball-Screw/Nut Axis Drive
A lead-screw with ultra-low friction between the spindle and the drive nut. An additional advantage is the high
accuracy of the pitch and minimal play between spindle and nut. It is mainly employed for the precision
movement of NC machine sideways, and has a high mechanical efficiency of about 98 percent.
BASIC
Short for Beginner’s All purpose Symbolic instruction Code, this is a high level programming language which is
easy to learn and particularly suited to solving mathematical problems.
Batch Processing
1. The technique of executing a set of programs so that each is completed before the next program is started.
Page 205 of 234

2. A method of processing jobs on a computer where they are organized and handled sequentially. This is the
opposite of timesharing where there is ready access to a computer
Baud
Transmission speed of data, measured in bits per second.
BCD
Binary coded decimal. Each digit of a decimal number is represented by a binary number of at least 4 bits : 379 in
BCD notation is 0011 0111 1001, for example.
Bi-directional Flow
In flowcharting. flow that can be extended over the same flow line in either direction.
Binary
1. Pertaining to a characteristic or property involving a selection, choice, or a condition in which there are two
possibilities.
2. Pertaining to the numbering system with a radix of two.
Binary Numbers
A numerical system in base 2 (as opposed to the conventional decimal system in base(10). The place value of
each individual digit is given by a positive or negative power of the number
2. For example, in the usual decimal notation 51 = (5x101) + (1x100), while the binary number is :
110011 = ( 1x25) + (1x24) + (0x23) + (0x22) + (1x21) + (1x20) = 32 + 16 + 0+0+2+1=51
Since only two characters are used (0 and 1), binary numbers can be easily represented-for example, by the
position of an ON/OFF switch or by hole/no hole in a puch tape or punched card, by the arrangement 1 = hole,
0=no hole, individual characters can be represented in encoded form via various hole patterns.
Bit
A contraction of binary digit. this is the smallest unit of information, usually expressed as 1 or 0.
Block
1. A group of words, characters, or digits handled as a unit.
2. A collection of contiguous data recorded as a unit. Blocks are separated by block gaps and each block may
contain one or more units of data
3. A group of bits or binary digits transmitted as a unit. An encoding procedure is generally applied to the group
of bits or binary digits for error control purposes.
4. Some-times means 128 bytes of storage area.
Boolean Algebra
A process of reasoning, or a system of the ores, using a symbolic logic and dealing with classes, proposition, or
ON/OFF circuit elements. It employs symbols to represent operators such as AND, OR, NOR, or NAND to permit
mathematical calculation.
BTR Input
Abbreviation for behind the tape-reader input. Connection for the direct input of control data via data lines
“behind” the punch-tape reader. It is used, for example in DNC systems.
Bus (Business Line)
A bi-directional data transmission link between several modules or components of a processor-controlled

electronic system. Mostly a bus line is divided into address bus, data bus, control bus, and so on.
Page 206 of 234
Byte
Group of 8 bits. A sequence of adjacent binary digits operated on as a unit. A series of computer binary bits
organized together to hold a symbol letter or number is a computer. Sometimes called a “word”. A word may be
comprised of 9,12 or 15 bits, for example. In describing the memory or logic capacity of a computer, terminology
such as “8K, 9-bit words” could be used.
Bezier Curve
A Polynomial curve passing near but not necessarily though a set of given points. Represents an equation of an
order one less than the number of points being considered.
Bitmap
The digital representation of an image in which bits are referenced (mapped) to pixels. In colour graphics, a
different value is used for each red, green and blue component of a pixel.
Bspline Curve
A blended piecewise polynomial curve passing near a given set of control points. The blending functions provide
more local control as opposed to curves like Bezier.
Buffer
An intermediate storage device (hardware or software)between data handling units
Block Delete
Permits selected blocks of code to be ignored by the control system.
CAD
Abbreviation for computer-aided design
CAM
Abbreviation for computer-aided manufacturing, denoting the use of computers in different areas of
manufacturing, such as for the control of material flow or machine control.
CAM-I
Abbreviation for Computer Aided Manufacturing international, INC., the continuation in development of, and the
replacement for the APT long range program.
Canned Cycle (Fixed Cycle)
Several fixed, frequently used machine or program functions, such as tools changing pallet changing, or drilling
operations, which a permanently stored in the control and which can be initiated by a single command in the
part program (G-funcion).
Cartesian Coordinates
The definition of a point in space by means of a system of three orthogonal axes, designated X,Y, and Z
Cell
The smallest flexible manufacturing unit, consisting of one or two CNC stand-alone machines, complemented by
ancillary equipment (such as auto-tool change) and providing unmanned operation for a very limited period.
Channel Structure
The structure of a CNC which permits the distinction between synchronous main axes, which require coordinated
interpolation and the asynchronous auxiliary axes.
Character
Page 207 of 234

A letter, digit, or other symbol that is used as part of the organization, control, or representation of data. A
character is often in the form of a spatial arrangement of dots or connected strokes.
Chip
1. In machining, a particle of material removed from a work piece as a result of processing operation to alter the
shape of the raw material.
2. In electronics, an integrated circuit mounted on a base to enable connection into a larger circuit.
CIM (Computer-Integrated Manufacture)
No Universally accepted definition exists, but CIM is generally taken to imply computer-assisted monitoring and
control of all aspects of a manufacturing business, thereby providing a source of rapid information flow from
which optimal operating decisions can be made.
Circular Interpolation
The calculation of the points on a circular contour, which is specified only by th start and end points and center
point or radius. Usually, circular interpolation is performed in a two axis plane (XY,XZ,YZ) and not in free space.
Closed-Loop ON/Off
A control circuit, where a feedback signal is used to switch something on or off when a certain target value is
reached.
C MOS
Abbreviation of “complementary MOS”, a semiconductor drawing negligible current.
CNC
Numerical control with one or more integrated microcomputers, used to perform all control functions. Also
called “Soft wired NC” Because of the capability to change software in the computer memory.
Code
A set of unambiguous rules specifying the way in which data may be represented.
Code Converter
Converts digital input signals of one code into digital output signals of another code.
Code Format
The arrangement of hole combinations in a column o a punch tape to represent a specific character.
Code Inspection
NC control function of a programming device in order to eliminate incorrect characters from the punch tape.
Every step of the punch tape input is checked for: a) an odd number of holes for a character in the EIA code
(parity check) and, b) the meaning of each character, that is, testing for a hole combination permitted by the
programming protocol.
A deviation triggers the tape error or programming error indicator and stops the programming error indicator and
stops the programming equipment or control. Path or switching data with incorrect values are not identified by
code inspection.
Command
1. An item of information which determines which branch of an algorithm or application program will be used.
vaguely distinguishable from an instruction by being in data stream rather than in the text or by being specified
on line rather than off-line. Distinguishable from data which usually does not affect the branching in an
algorithm.
Page 208 of 234

2. A control signal.
3. An instruction in machine language.
4. A mathematical or logic operator.
Comparator
A computer program used to compare two versions of the same computer program under tes.
Compatibility
The degree to which output languages/programs from punch tapes or magnetic tapes, and components from
different systems can freely interacted. Two devices are compatible if they can communicate without any
additional interfacing equipment being necessary.
Compiler
A computer translator program that transforms a higher-order language source program into an assembly
language format for subsequent transformation to machine language by an assembler.
Computer
Basically, a computer is a data processing device with the capability of carrying out calculations and logic
operations. After specific input data is provided, the computer will process the data to provided, the computer
will process the data to provide the desired output.
Computer-Aided . . . (CA. . .)
Abbreviation for all computer-aided technologies, for example:
CAD = Computer-aided design
CAE = Computer-aided engineering
CAM = Computer-aided manufacture
CAPP = Computer-aided process planning
CAQ = Computer-aided quality assurance.
Computer-Aided Programming
Preparation of a part program with the aid of a computer. Again with computer aid, a processor and
postprocessor program is then produced in a special programming format suitable for input into the NC machine
tool.
Console
1. The main operator control center of the computer. Usually the results of all operations, indicators, and general
conditions are available at the console.
2. That part of computer used for communication between the operator and the computer.
3. Usually the unit containing the external side of a device where controls and indicators are available for
manual operation of that device.
Continuous Path Control
A form of numerical control where the relative movement of tool and component along the required path is
continuously controlled. Continuous path control is achieved by the coordinated simultaneous operation of two
or more machine axes. Path controller employ interpolators for this purpose. They calculate the exact path
contour according to the start and end points of the path elements. ( For circular paths either the center point
or the radius is also required.)
Controller
Page 209 of 234

An apparatus of unitized or sectional design, through which commands are introduced and manipulated.
Control Loop Circuit
A system in which an output signal is fed back to the input point and then compared with the input signal.
Converter
A device capable of converting impulses from one mode to another, such as analog to digital, parallel to serial, or
one code to another.
Coordinate
An ordered set of data values, either absolute or relative, which specifies a particular location.
Coordinate Measuring Machine (CMM)
A computer controlled measuring machine which can be used o inspect a work piece, whereby the individual
coordinate values are measured numerically and indicated digitally.
Core Memory
A read-write memory which consists of ferromagnetic rings arranged in a wire matrix. Each ring stores one bit of
data.
Counter
A device such as register or storage location used to represent the number of occurrences of an event.
CPC/CPL
Abbreviation for customer programmable cycles or customer programmable language . This is a gesture offered
by most modern CNCs, enabling customers to write their own machining cycles or macros in a high-level
programming language (BASIC, PASCAL, or a hybrid language).
CPU
Abbreviation for central processing unit. The CPU is the heart of any computer, and consists of the processor,
controller, and register. A CPU can be made up of either discrete components, an IC, or a microprocessor with
memory modules.
CRT (Cathode Ray Tube)
A vacuum tube, much like a television screen, within which a beam of electronics is focused to a small spot on a
luminescent screen and deflected by high voltage to trace output graphics. Some CRTs, called storage tubes, can
hold images on the screen continuously without electron-beam retracing.
Cursor
A movable electronic pointer on a VDU screen, generally displayed as a blinking point or dash. It helps the
operator with orientation on the screen, especially during editing of input data.
Cutter Compensation
A means of adjusting the cutter on a numerical control system to compensate for the variance actual cutter
radius from the normal programmed cutter radius.
Cutter Location File (CL File/CL Tape/CL Data)
A data set which defines the cutter center line path. This data must be post processed in order to convert the CL
data into a part program for a specific machine tool.
Cutter Path
The path followed by the center line of a cutting tool as the part is being cut to the desired dimensions.
Cycle
Page 210 of 234
Any set of operations that is repeated regularly in the same sequence. The operations may be subject to minor
variation on each repetition.
Cycle Time
1. An interval of time in which one set of events or phenomena is completed.
2. The minimum time necessary for a CNC to prepare program blocks for their processing. When processing time
is shorter than cycle time the machine is stationary until the next block can be processed, and the resulting
operation data downloaded. However, such standstill situations can be avoided by reducing machine feed rate.
CAE
Abbreviation for computer-aided engineering, which uses grafics-oriented computers software for engineering
and drafting applications involving mathematical analysis.
Cancel
A commend that nullifies any canned cycle or sequence commends.
Cartesian Coordinates
A mean whereby the position of a point can be defined with reference to a set of axes at right angles to each
other.
Chamfer
A beveled edge or corner between two intersecting lines or surfaces.
CIE
Abbreviation for computer-integrated engineering or computer-integrated enterprise.
Control Key
A key on the keyboard used in conjugation with other keys to perform special functions.
Coons Patch
A Bicubic surface patch interpolated between four adjoining general space curves.
Cross-hairs
A cursor usually comprising two perpendicular lines on the display screen and used to select coordinate
locations.
Cutter Diameter Compensation
Provides a means of using a cutter of a different diameter than originally intended in a program. The programmer
may use either an oversized or undersized cutter and still maintain the programmed geometry
Data
A representation of fact, concepts, or instructions in formalized manner suitable for communication,

interpretation, or processing by human or automatic means.
Data Carrier
A physical medium on which data can be stored for later retrieval; punch tape, magnetic tape, or diskette, for
example.
Data Processing
Carrying out a systematic series of calculations or other logical operations according to specific data to derive
further data, to place them in a certain format, or to control other devices-numerically controlled machine tools,
for example.
Page 211 of 234

Data Resolution
The minimum resolution of a control or measuring system, for example, 0.0001 in.
Data Storage
The electronic storage of data on a data carrier or other storage device, from
which they can be retrieved at will.
Datum Offset (Zero Offset)
The capability of shifting a datum point.
Datum Point
A particular point from which individual coordinate dimensions are referenced. See also, zero reference point.
Dead Zone
A well-defined zone in which a change of input signal does not cause a change in output signal.
Debugging
The process of identifying errors in programs by means of either special debugging programs, or any laborious
manual means, see also, editing.
Decade
The distance between two variables in a relationship of 10:1.
Decade Switch
Has ten switching positions, with values from 0 through 9. They are often employed in decade switch groups,
thus permitting the manual setting of a parameters to any required numeric value, provided the number of
switches equals the number of digits of switches equals the number of digits of the decimal number. They are
mostly used for the presetting of target values for certain machine positions or tool compensations.
Decimal Point Programming
Path measurement input using decimal point instead of leading or trailing zeros.
Examples :
417 instead of 417 000 .75 instead of 750
.1 instead of 100 .001 instead of 1
The advantage of decimal point programming is not that tapes are shorter, but that manual data input is more
convenient and less prone to error.
Dedicated Computer
A computer which is dedicated to a specific task. For example, in a DNC installation a computer is dedicated to a
group of machines, whereas in a CNC it is dedicated to a single machine.
Deviation
Deviation of an actual value from its target value. An example is the difference between the actual path and the
programmed path of a cutting tool (defined as dynamic path deviation), which impairs piece part contour
accuracy.
Diagnosis
A special feature of computers of CNCs which permits the localization of program error with the aid of the
screen display. Software features such as logic analyzers, PLC monitor, multiple channel oscilloscope, comparison
of target and actual values, and graphic display of measured values all belong in this category.
Page 212 of 234

Dialogue
In relation to NC, the designation of a data input method in which the operator is “led” by the control, that is, the
data required for positions, parameters, and additional information are requested from the operator by the NC
Unit via a display screen menu.
Differential Resolver
A position encoder consisting of a transformer with two secondary winding in which reciprocal voltages are
produced and are dependent on the position of the primary winding or the magnetic core.
Digit
1. A symbol that represents one of the nonnegative integers which is small than the base. For example, in
decimal notation, a digit is one of the characters from 0 through 9, synonymous with numeric characters.
2. See binary numbers.
Digital
Relating to digits, operating by the use of discrete signals to represent data in the form of numbers or other
characters. The display of information as numbers in a specific code.
Digital Data
Information represented in a discrete ( discontinuous) form and transmitted by such means as the presence or
absence of a voltage, the presence or absence or a hole on a punched tape or card, or a contact in the open or
closed position.
Digital Input
Input data in the form of digits which are entered manually or automatically via punch tapes or from a magnetic
storage medium.
Digital Readout, Numerical Display
The desired target location or the actual location of one or more axes is visually displayed as a decimal number.
Digital -to-analog (D/A) converter
A device which transforms digital data into analog data.
Digital Measuring System
A measuring system which measures discrete values in either incremental or absolute format.
Digitizer
1. A device for converting positional information into digital signals. Typically, a drawing or other graphic is
placed on the measuring surface of the digitizer and traced by the operator using some form of cursor or
stylus. Frequently, an alphanumeric or function keyboard is also provided for inserting supplementary
information which aids in defining the elements of the drawing. A digitizer may output to any standard
peripheral device such as a card punch or magnetic tape unit. It can be interfaced directly to a computer and
used interactively in conjunction with a display
2. A device that converts graphic representations to digital form, i.e., Data Tablet.
Direct Measurement
A measuring system which does not convert linear slide movement into a rotary movement.
Direct Numerical Control (DNC)
The use of shared computer for distribution of part program data` via data lines to remote machine tools, and
other NC equipment in the system.
Page 213 of 234

Diskette
A flexible disk of oxide-coated mylar stored in paper or plastic envelopes. The entire envelope is inserted in the
disk unit. When the diskette is being read or written to, the plastic disk is rotated within a disk drive unit.
Diskettes provide low cost storage for microcomputers and minicomputers.
DOS
Abbreviation for disk operating system; a disk-orientated operating system for computers which predominantly
uses disks for storage of programs and data.
Dwell
A timed delay of programmed duration not cyclic or sequential, that is, not an interlock or hold. Dwells of
specific durations may be specified by preparatory G-function G04.
Database
Related information organized and stored so that it can be easily retrieved and, typically, used by multiple
applications.
Default
A parameter or variable that remains in effect until change. It is what a computer program assume in the absence
of specific user instructions.
Digitizing Tablet
A graphical input device that generates coordinate data. It is used in conjunction with a puck or stylus.
Directory
A portion of the storage space on a disk drive that can contain files. It is analogous to a file drawer in a filing
cabinet.
Display screen
A video display tube or CRT used to transmit graphical information.
Drawing File
A collection of graphical data stored as a set (file) in a computer.
DXF
Abbreviation for drawing interchange file. A file format used to produce an ASCII description of an AutoCAD
drawing file.
Editing
The process of correcting or optimizing a part program by editing, removing, or modifying individual characters,
words, or blocks of information in the program. See also, debugging.
EIA Standard Code
A standard code for point-to-point, linear path, and continuous path controls proposed by the U.S. Electronic
Industries Association in their standard RS. 244. It uses a punched tape input medium which is one in, wide and
has eight tracks.
Electronic Hand-wheel
A small integrated hand-wheel found on the operating panel of modern CNC controllers. It can be used in the
setup operating mode to finely adjust individual axes, and is the electronic equivalent of the mechanical hand-
wheels found on conventional machine tools.
Encoder
Page 214 of 234

A type of transducer commonly used to convert angular or linear position into digital data. See also , resolver.
Encoding
Translating of data from a program tape onto a punch or magnetic tape.
End of Block (EOB or $) Character
A character entered on a program tape to denote the end of a block of data
End-of-File Mark (EOF)
A code which signals that the last record of a file has been read.
EPROM, EEPROM
Electronic memory module which permits the deletion of data stored on it, either electronically (EEPROM) or by
means of ultraviolet light (EPROM).
Error-Detecting Code
A code in which each expression conforms to specific rules of construction. Therefore, if errors occur in an
expression, their presence is detected.
Error Signal
Differential voltage which is produced by the positional deviation between a preset target value and the actual
value measured.
Executive Program
The software for the microprocessors of a CNC, which achieves its desired functionality. It contains all the
operational features of the controlled and is developed by the CNC manufacturer.
External Interpolation
1. A computer which is separate from the CNC performs all interpolations for linear, circular, or parabolic cutter
paths. The resulting path data are
then entered into the CNC where they can be more quickly processed. A storage medium commonly used for
this purpose is magnetic tape.
2. An external calculations which deduces larger linear and circular paths for a sequence of points, and thus
reduces the amount of input data to a path-control system with internal interpolations.
External Storage
1Data storage which is not integrated into the central processing unit of computer often designed as mass
storage (disk, tape, or RAM)End Point The exact location on a line or curve where it terminates.
Enter
A keyboard key that when pressed signals the computer to execute a command or terminate a line of text. Also
sometime called Return.
Family of Parts
A group of parts of similar geometry, which can be machined by similar machines and tooling without major
changes to the setup of the machine tools. See also, group technology.
Feedback
1. Change in input information of a system as a function of the output information of that system.
2. The concept of obtaining information from real experience and feeding it back into the planning and
appropriate initial storages to improve system efficiency.
Page 215 of 234

Feedback Loop
The part of a closed-loop system which feeds back a measured actual value for comparison to the target value.
Feed-Rate Control
A capability for controlling the feed rate manually or via tape.
Feed-Rate Override
A function which allows the operator to manually alter the feed rate by a desired percentage (usually 10-120
percent) of its programmed value.
File
Precisely defined region in the memory of a computer where data which are to be reused are stored. Typical NC
examples are tool data files, material specification data files, and cutting tool data files.
Firmware
The control functions which are stored in the read-only memory (ROM), or in the micro program of the CPU, are
referred to as firmware and include functions like multiplication and division. In contrast to the operating system
of a computer firmware is not considered to be part of the operating software.
Fixed Sequential Format.
An NC tape format whereby each word in the format is identified by its position. Every word must be stated
even though it is repeated from the previous block.
Fixture
A mechanical device for holding a piece part in a precisely defined position during the machining process.
Flexible Manufacturing System (FMS)
Machine tools which are closely linked to each other, for example by means of robots or automatic guided
vehicles for component handling, and controlled by computers which coordinate the operation of all the items in
the system. FMSs are employed in the automated manufacture of part families of any lot size.
Floating Zero
A characteristic of a numerical control system which allows the zero reference point to be established at any
position over the full travel of the machine tools. See also, zero offset.
Floppy Disk
Another name for a diskette.
Flow chart
A diagram which shows the structure and organization of a computer program and which specifies the sequence
in which individual steps and subroutines are performed.
Format
A specific arrangement of data the physical arrangement of data on a program tape and the overall pattern in
which it is organized and presented.
FEA
Abbreviation for finite element analysis. Numerical technique of approximately determining field variables such
as displacements and stresses in a domain. This is done by breaking down the domain into a finite number of
“pieces”, also called “elements”, and solving for the under known in those elements.
Feed
The programmed or manually established rate for movement of the cutting tool into the work piece.
Page 216 of 234
FEM
Abbreviation for finite element modeling. The process of breaking down a geometric model into a mesh, called
the finite element mesh model, that is used for finite element analysis.
Fillet
A curved surface of constant radius blending two otherwise intersecting surface. A two-dimensional
representation of this surface above involving two lines or curves and an arc.
Geometric Data
All information in a part program which describes tool traverse motions.
G Function
A preparatory code in a program tape to indicate a special function. The code consists of the letter G and two
digits, which are pre-assigned to various functions, such as motion, delay, dimensional data coordinates and feed
rates.
Graphics
The use of a VDU screen as part of a CNC or an independent programming facility to provide graphics display of
data typical examples are input graphics for programming tasks including display of input corrections; simulation
graphics for program testing, sometimes with dynamic display of cutting tools used; auxiliary graphics for raid
ancillary information retrieval to help the operator/programmer; and diagnostic graphics as a debugging aid.
Group Technology
The technique of grouping parts together that require similar manufacturing operations and not necessarily
based on component shape. See also, family of parts.
G-Code
A word addressed by the letter G and followed by a numerical code defining preparatory functions or cycle types
in a numerical control system.
Generation, NC
Typically refers to the automatic generation of NC instructions from a CAD model of part geometry.
Grid
An area on the graphics display covered with regularly spaced dots and that is used as a drawing aid.
Handling Unit
A robot or other mechanized device used for loading and unloading a machine, or for parts assembly.
Hard Disk
Encapsulated magnetic system for large scale storage of data (sometimes called a Winchester disk). It has a
much higher memory capacity than a diskette, and is permanently installed in the computer.
Hardware
1. physical equipment and peripherals of a computer system, including mechanical magnetic, electrical or
electronic devices. Contrast with software.
2. The tangible instruments of data processing system
Hard-Wired
A CNC system which processes control data via hard-wired circuits and logic modules. Modification of the
system is only possible by physically changing the wiring or exchanging modules.
Hexadecimal
Page 217 of 234
A number system having the base of 16, predominantly used in computing. One hexadecimal digit is equivalent
to a group of four bits. For the first ten digits the numbers 0 through 9 are used, the further six digits being
represented by the first six letters of the alphabet (written in upper case letter A to F).
Decimal Four Bit Group Hexadecimal
0 0000 0
1 00001 1
3 0011 3
7 0111 7
9 1001 9
10 1010 A
11 1011 B
12 1100 C
13 1101 D
14 1110 E
15 1111 F
Home Position
The fixed “datum position” of each machine axis. It is generally the position in which the axis is completely
retracted so that maximum physical access to the machine is possible. The home position is often coincident
with the zero point of the axis.
Hose Computer
The computer which is highest in the hierarchy of an FMS. It coordinates all program data flow, piece part
transportation, tool management materials handling, and inspection, as well as creating management reports as
required.
Hardcopy
A paper printout of information stored in a computer.
Hatching
A regular pattern of segments covering an area bounded by lines and/ or curve..
Impulse
Short electrical signal (us, ms) for the control of certain functions, numbering processes, and so on. Examples :
Read impulse from a reader into the data memory ; path measurement impulses from an incremental measuring
system to the counter in the control. For interference-free processing of impulses it is necessary to have the
highest possible signal-to-noise ratio of utilization signal to interference signal
Increment
The quantity by which the value of a variable increases or decreases from one position or step to the next
Incremental Coordinates
In computer graphics, the coordinate measured from the preceding coordinate in a sequence of values.
Page 218 of 234
Incremental Dimension
A dimension measured from the preceding point in a series of points as opposed to an absolute dimension in
which each point in a series would be dimensioned from a single reference point.
Incremental Jog
The capability of displacing distance in small increments.
Incremental System
1. A control system in which each coordinate or positional dimension, both input and feedback is taken from the
last position rather than from a fixed datum point.
2. Programming whereby each coordinate location is given in terms of distance and direction along rectangular
axes from the previous position and not from a fixed zero location
3. Indirect Measurement Measuring principle in which a rotating measuring system is driven via screw/nut or
rack and pinion devices. In accuracies of the mechanical transmission elements impair measurement accuracy.
Inductosyn
Trademark for farrand Controls analog position transducer. Available in linear and rotary versions for higher
precision positional measurement. the electrical output signal is produced by inductive coupling between scale
and slider.
IN-Process Ganging
Measurement control of a work piece during computer-aided machining. Adaptation to numerically controlled
machine tools enables the control to compensated for external influences like tool wear, thermal expansion, and
other factors which are not controlled on conventional machines.
Input
1. Set of possibilities
2. Pertaining to a devices, process, or channel involved in the insertion or transfer of data or information into a
computer or machine control unit
Input Data
Coded instruction for the input into an NC controller via punch tape, magnetic tape, diskette, downloading from
a DNC link, or direct manual input at the machine tool’s controller
Integrated Circuit (IC)
A circuit made up of semiconductors integrated into a single chip of standardized size.
Interface
The I/O module between different parts of a system, particularly between a machine tools and its control. Its
functions are to decode, interpret, combine and match electronic signals. Modern control use programmable
interfaces, where these functions are achieved via software.
Internal interpolations
The calculation of the points on a linear, circular, or parabolic contour carried out within the numerical controller
itself. The start and end point of the contour, plus any necessary auxiliary points, are the only input data
required by the CNC
Interpolation
Page 219 of 234

The passing of a curve or surface precisely through a set of data points, and /or by the insertion of intermediate
information based on a assumed order or computation (for example, cutter paths are controlled by interpolation
between fixed points by assuming intermediate points are on a line, a circle or a parabola). In NC curved sections
are approximated by the series of straight lines or parabolic segments
Interrupt
The interruption of a program at a specified positions for a finite period of time for the call-up of a subroutine, for
example. After the interruption, the program is continued from the interrupt point.
Island
A segregated are of the shop wherein several CNC machines and associated equipment are dedicated specially
to machining a specific family of parts.
ISO Code
Standardized 8-track punch tape code with 7 data bits and one test bit in track 8.
ICON
A graphical symbol typically used to convey a message or represent a commend on the display screen.
IPM
Abbreviation for inches per minute.
IPR
Abbreviation for inches per revolution.
ISO
Abbreviation for international Sanitation Organization. An organization charged with establishing and promoting
international standards.
Isometric
A view or drawing of an object in which the projections of the X,Y, and Z axes are spaced 120 degrees apart and
the projection of the Z-axis is vertical.
JOG
A control function that manually operates an axis of the machine.
KByte
Abbreviation of kilobyte; unit of the storage capacity of a computer. One kilobyte contras 1024 bytes (2 to the
power of 10)
Language
A set of symbols, conventions, and rules used to convey information
Light Emitting Diode (LED)
A semiconductor which emits a colored light beam, and can be used instead of colored light bulbs.
Linear Interpolation
/the calculation of the points on a straight line, defined only by the start and end points. A distinction is made
between linear interpolation by switching from one plane to the other (2 1/2-D), and linear interpolation in space
(3-D).
Linear Path System
Page 220 of 234

A point-to-point control with the capability of controlling the feed rates for movements in directions parallel to
the axes of the machine, for straight-line milling. for example. The principle of linear path control is the control of
parallel axis movement.
Logic
A system of computational components based on the basic switches either/or, of/off, and so on. since only two
conditions are possible , bistable devices can be used (relays, diodes, and so on).
Looped Tape
A system in which punch paper tape drops into chute after its pass through the reader without being respooled.
The beginning and end are joined together so that a continuously repeating pass-through is possible.
LSI
Abbreviation for large scale integration which denotes the integration of several chips into one single complex
chip.
LAN
Abbreviation for local area network. One of several systems used to link computers together in order to share
data, program, and peripherals.
Letter Address
The manner by which information is directed to the system. All information must be preceded by its proper letter
address, for example X,Y,Z or M.
Machine Reference
A machine position which can always be located by the measuring system, even after power failure or program
cancellation.
Machine Center
A multifunctional NC machine tool with automatic too changing, automatic work piece changing and the
capability of a wide variety of operations on up to five sides of a prismatic work piece in a single setup.
Macro
A sequence of instructions (control data) which are stored and called up as one integral unit, canned cycles, for
example.
Magnetic Tape
A data carrier or data storage medium which consists of plastic tape with a ferromagnetic surface coating. It is
generally used in the form of standard or minicassettes or cartridges for data input and output to and from Ncs
Management Information
General term to encompass information covering all aspects of, in this context manufacturing management, such
as materials handling operations, transportation times, setup and machining times, down times and their causes,
lot sizes processed manufacturing quality statistics and assembly times.
Manual Data Input (MDI)
Manual insertion of part program data into the controller at the machine tool, Modern MDI controls have
integrated programming aids and a graphics screen to simplify parts programming at the machine tool.
Manual Programming
The preparation of a part program in program format for a certain machine/NC combination without use of
computer aids.
Page 221 of 234

Manuscript
A form used by a part programmer to organize work piece machining instructions. From this a program tape is
punched or a computer program s prepared
MAP
Abbreviation for manufacturing automation protocol. Map is the name of a project initiated by General Motors
to link independent manufacturing islands, thereby permitting continuous data flow through out the company. It
has now been internationally adopted. MAP also aims to ensure that all data and information from the order
receiving department through hob planning materials handling, manufacturing, quality assurance, and accounts
shall all use universally exchangeable data based, via the used of standardized manufacturer independent
interfacing.
Measuring System
A transducer of a system of transducers necessary for measuring a machine’s movements
Menu
A selection of instructions or possibilities offered to the user by the computer and displayed on a VD screen in
the most user-friendly form
M Function
Under the miscellaneous M address, programmable on-off functions such as spindle stop, coolant on/off, and too
changing are controlled. Also called auxiliary functions.
Microcomputer
A microprocessor with program memory, working memory, and an input/output unit is termed a microcomputer,
and is the minimum configuration of a working system additionally, every microcomputer also needs the
appropriate software to control it in the performance of its required tasks. Memory capacity ranges from 640 to
4000K bytes.
Microprocessor
A large scale integrated circuit performing the basic functions of the central processing unit of a computer. It
basically consists of an arithmetic unit, various working registers, and a sequence control. To work correctly, a
microprocessor needs additional memory modules for program and data storage.
Milling Cutter Radius Compensation
A manual adjustment of regulating capability for varying milling cutter radial which arise, for example, from
regrinding or use. With this capability, the path of the milling cutter center point can be altered to allow for
unavoidable deviations from the nominal size used in the program.
Minicomputer
The size of a computer is not determined on storage capacity. Minicomputers have a memory capacity of
approximately between 8000 and 256,000K bytes, while mainframe system have a minimum capacity of about
512,000K bytes. Such large computers permit the rapid processing of extensive and complex calculations.
Mirror Image Operation
By reversing the direction of only one axis of a machine tool, two mirror image work-piece can be produced from
the same input data. Mirror images can be produced in al quadrants.
Modal
The structure of NC data blocks permits the use of two types of words. Commands in the form of modal words
remain effective until they are deleted or replaced by other commands. No modal words are effective only once
in an instruction, and have to be repeated if required again.
Page 222 of 234

Modem
Abbreviation for modulator/demodulator; a device used for data transmission. It converts data from one format
to another, for example, it converts characters in an 8-track code into bit-serial impulses for data transmission
down telephone lines.
Moire Fringe
An effect caused by the opposing movement of two similar optical grids perpendicular to the grid lines. This
interference effect consists of alternating light and dark patterns or bands which produce a cyclical bright/dark
image as movement proceeds. since these lines are basically enlarged pictures of the pitch (grid constants), they
can be ready by photoelectric system and differentiated based on movement direction. this results in a highly
accurate measuring method for small movements.
Monitor
VDC screen for the display of operations, results data, and so on in the form of text or graphics.
MOS
Abbreviation for metal oxide semiconductor; a semiconductor with a very high electrical input resistance.
Mainframe Computer
Arguably, a larger and faster computer than a minicomputer.
MCU
Abbreviation for machine control unit. Consists of the electronics and hardware that reads and interprets the
programmed instructions and converts it into the mechanical actions of the machine tool.
Memory
An essential components of a computer. The place in which programs and data are stored. Memory includes both
ROM (read only memory) and RAM (random access memory)
MPM
Abbreviation for millimeters per minute.
MPR
Abbreviation for millimeters per revolution.
Minicomputer
A computer that is generally configured for simultaneous use by a small number of people. It generally has more
powerful resources and peripherals than does a microcomputer.
Mode
A software setting or operation state.
Model
A two-or-three-dimensional representation of an object.
Modem
Stands for modulator/demodulator. The device that allows a computer to send and received data over telephone
lines.
Mouse
A hand operated, relative-motion device resembling a digitizer puck and used to position the cursor on a
computer display screen.
Page 223 of 234

Multi-user
The ability of an operating system to allow multiple users on different terminals to share computer resources
such as the CPU, storage, and memory.
Multitasking
The ability of an operating system to mange concurrent tasks on a computer.
Numerical Control (NC)
An electronic system to control movements of a machines tools through the insertion of numerical data. The
system interprets these data and converts them into the appropriate electrical signals in order to cause the
desired movements or actions at the machine tools.
Numerically Controlled Tool change
A system which allows different cutting tools to be located and placed in the machine spindle on demand.
Numerical Control System
A system in which a program of instructions is read by a machine control unit and decoded to cause movement
in a machine tool or to control a process.
Network
An electronic linking of computers for communication.
NURBS
Stands for Non-uniform Rational B-splines. A widely used parametric model for three-dimensional curves and
surfaces.
Object Program
A program in the binary code which can be loaded directly into a computer and is thus immediately executable.
The output of an assembler processor is always an object program.
Off-Line Operation
An operation carried out independently of the main computer.
1. Pertaining to equipment or devices not under direct control of the central processing unit
2. The CPU or MCU operates independently of the time base of the actual inputs; that is considerable time may
elapse between an input to the computer and the resulting output. It can also mean operation of peripheral
equipment independent of the central processor of a computer system.
On-Line Operation
An operation carried out within the main computer system.
1. Pertaining to equipment or devices under direct control of the central processing unit.
2. Operation where input data is fed directly from measuring devices into the CPU or MCU. Results are obtained
in real time; that is computations and operations are based on current data to permit effective control action. It
can also mean the operation of peripheral equipment is conjunction with the central processor of a computer
system.
Open Loop System
A system which generates output signals but relies on the integrity of the system to execute them. There is no
feedback for monitoring purposes.
Operating System
Page 224 of 234

One or more programs which control this operation of a computer. It is the operating system that makes the
processing of specific programs possible and manages the operations of the computer.
Output Signal
Current or voltage output, or mechanical force, provided by a control in order to meet a specific function.
Overshoot
The condition that occurs when a variable exceeds its target value.
Offset
A displacement in the axial direction of the tool that is the difference between the actual tool length and the
programmed tool length.
Origin
The intersection point of the axes in a coordinate system. For example, the origin of a Cartesian coordinate
system is where the X-,Y- and Z-axes meet, at (0,0,0,).
Orthogonal
Two geometric entities whose slops or tangents and perpendicular at their intersection.
Orthographic Projection
Also called the parallel projection, the two-dimensional representation of a three-dimensional object but without
perspective. In drafting, it is typically the front, top and right-side views of an object.
Pallet
A portable piece part holder. Jobs are usually loaded and unloaded remotely from CNC machines, and they
remain on their respective pallet throughout the machining procedure. The use of programmable automatic
pallet changers now makes it possible to cut to a minimum unproductive machine downtime normally require to
align, clamp, load and unloaded each job.
Parallel Axis
The simultaneous control of two or more mechanically independent axes which are parallel to each other. For
example, if parallel motion to Z is desired, such as in the control of two spindles on one machine tools, then a
secondary axis must be designated as being parallel to Z which in this case would be W.
Parallel Data Input
The simultaneous transmission and input of information in the 8-track or 16-bit format via 8 to 16 parallel channels
- the alternative to serial data input.
Parallel Input Mode
In this programming mode new part programs are written via a CNCs manual data input control , at the same
time as the NC machine continues to produce a different part, controlled via the same NC controller.
Parametric Programming
NC programming by means of parameter input only-for example, the relevant parameters for holes on a certain
pitch circle diameter are the pitch diameter, the number of holes, start and increment angles, and he appropriate
drilling cycle. The system then automatically determines all necessary data from just these few input parameters.
Parity Check
A method for checking binary data for syntax error, that is, to identify incorrect characters in a punch tape or in
data transmission. An additional bit, the so-called “ parity bit,” is added to certain characters in order to keep the
number of bits per character even (ISO code) or odd (EIA Code)
Page 225 of 234

Part Program
Specific and complete set of data and instructions for the purpose of manufacturing a part on an NC machine
tool.
Path Data
All data which are necessary to achieve a certain relative position or movement between tool and work piece.
the programmability of dimensional numbers (geometrical data) is a basic characteristic of numerical control. the
path data are taken by the programmer from the design drawings of the components to be machines, and then
they are entered in such a way that the paths or positions of the tools with respect to the piece part are clearly
described.
Path Measuring System
There are to different types of system:
1. The position measuring system issues the coordinate value of machine axis position in absolute form, e.g., via
encoded measuring systems or a resolver.
2. The path measuring system measures the increase in traveled distance of each axis movement e.g. through an
incremental impulse encoder in combination with an electronic forward/reverse counter.
A stationary, path measuring system is needed for each numerically controlled axis.
Peck Feed
An automatically programmable feed system for deep hole drilling, where the normal feed rate movement is
interrupted by rapid reverse in the direction of feed at preset intervals in order to allow the generated chips to
be removed from the hole. The drill then returns to its last cutting position where it begins to operate at the
normal cutting feed rate for another period of time.
Peripheral Equipment
Any unit of equipment, distinct from the central processing unit, which may provide the system with outside
communication.
Photoelectric Line Tracer
A device used for copying profiles directly from the drawing or controlling the path of burning heat of a NC
flame cutting machine
Pitch Correction Unit
A unit in a control which enables the correction of a pitch error in a lead screw or a rack and pinion gear.
Playback
The generation of control data for repeated automatic machining by manually machining the first work piece.
Plotter, XY
A device used in conjunction with a computer to plot coordinate points graphically.
Pocketing
A capability for removing (usually by end milling) metal from an enclosed surface upto a certain depth using a
single instruction instead of programming each single step.
Point-To-Point Control system
An NC system which controls motion only to reach a given end point but exercises no path control during the
transition from one end point to the next.
Point-To-Point Control With Straight Cut.
Page 226 of 234

A Point-to-point control with the additional capability to control feed rate along the coordinate axes. Such a
system can be used for straight milling operations parallel to the direction of the coordinate axes.
Polar Axis
Axial designation for circular table, rotational axes, and joint axes.
Polar Coordinates
A mathematical system of coordinates for locating a point in a plane by the length of its radius vector and the
angle this vector makes with a fixed line.
Position Readout
The visual display of the relative position of a machine axis (the distance from its zero point), which is measured
by a resolver or encoder.
Positive Positioning
A movement in the positive direction with reference to an absolute zero point.
Postprocessor
One of the most misunderstood terms used in NC. It is not a piece of hardware, but a computer program that
takes a generalized part program output and adapts it to a particular machine control unit/machine tool
combination.
Processor
In hardware, a data processor, I software, a computer program that includes the compiling, assembling,
translating, and related functions for a specific programming language; normally proceeds post processing.
Program
A collection of one or more computer-executable (directly or indirectly) procedures in general, the execution of
one main procedure and a number of sub procedures.
Program End
A function which causes the shutdown of the machine after the last block of a program has been processed. The
shutdown includes machine functions like coolant off, spindle off, tool retraction and retraction of the machine
axes to their initial positions.
Programmable logic Controller (PLC)
A sequence control which works like a relay control, but with a computer like structure. For programming the
control functions a special programming device is needed. The program logic is stored in RAM, PROM, or EPROM,
and defines the sequence and the manner in which inputs and outputs are to be connected.
Programming
The preparation of a listing of a sequence of events necessary to carry out a given task. The listing is written in a
form that can be readily interpreted and processed by a computer or NC unit.
Programming Aids
Computer-assisted systems or devices, which facilitate the programming of an NC machine. They perform
geometric calculations and check programs for bugs and syntax errors related to a specific NC
controller/machine tool combination.
Programming Language
An artificial language for writing computer programs.
Programming Method
Page 227 of 234

The way a program is structured. Manual programming leaves much methodology freedom to the programmer,
that is, the programmer can decide the order of the programming steps. Interactive programming systems with
computer assistance determine the programming step order automatically.
Programming System
Comprises all the components that a part programmer needs to fulfill his task. For example, an EXAPT
programming system consists of a computer, processor, postprocessor, and all data files and associated software
packages, as well as a puncher, Plotter and printer, However a TELEAPT system only comprises the input device
system only comprises the input device telephone modem a puncher, and a printer.
Programming Technique
The structured technique which is used for producing part programs, and which depends on the programming
system used. With manual programming systems the program sequence is written in the form of blocks in a
format suitable for direct input into the NC at the machine tool, but with computer-aided programming systems
the manufacturing process is described in a high-level programming language. With interactive programming
systems the description of the part contour is by means of either geometric elements or the geometric data of
the contour itself.
Programming Unit
The combination of an electric typewriter, a puncher, and a reader for the production of punch tapes (can punch,
check, copy, and print out the information data in a readable format.
Program Stop
An instruction in an NC program that will automatically stop the machine (M00, for example).
PROM
Abbreviation for programmable read-only memory; an electronic memory module which retains the once-and-
for-all programmed data, and permits its reading but not its editing or deletion.
Protocol
An agreed-on set of rules by which data interchange between computers and related numerically controlled
devices is formatted to enable them to freely communicate with total comprehension.
Punch Card
An input medium in the form of a card in which holes can be entered in certain patterns for storage and
transmission of data; now a largely obsolete data-carrier system.
Punching
Putting encoded data on a card or a punch tape in the form of punched holes.
Punch Tape
An input medium consisting of a paper or plastic strip in which encoded instructions are entered in the form of
punched holes. The tape contains eight possible data tracks as well as a transport track.
Part Program
A specific and complete set of instructions for the manufacture of a part an NC machine.
Peripheral
An accessory device to a computer such as a plotter, printer, or tape drive.
Pixel
Stands for “picture element”. Pixels and the tiny dots that make up what is displayed on a CRT . Also called “pels”.
Page 228 of 234

Preparatory Function
An NC command that changes the mode of operation of the control. (Generally noted at the beginning of a
block by the letter G plus two digits.)
Prompt
A message from the computer software requesting a response from the user.
Puck
A hand-operated device with one or more buttons resembling a mouse, it operates in conjunction with a
digitizing tablet. Also called transducer.
Quadrant
One of the quarters of the rectangular or Cartesian coordinate dimensioning system.
RAM
Abbreviation for random access memory; an electronic volatile semiconductor memory module which permits
random access. This is a contrast to a magnetic tape which permits only sequential access. Thus each sector or
segment can be addressed, for both reading and writing, individually.
Rationalization
The elimination of unnecessary equipment, personnel , or processes from a factory, in order to make it more
efficient. Rationalization makes it possible to save on raw material, capital and time. Automation is a final step in
rationalization.
Reference Point
A point defined within the limits of travel to locate an axis or the spindle in relation to the part.
Repeatability
1. A measure of hardware repeatable accuracy.
2. Closeness of agreement of repeated positional movements to the given indicated location. See also accuracy
Reproducibility
The closeness of agreement between repeated output measurements for a given input valves made under the
same operating conditions over a period of time, approaching from either the positive or negative direction.
Resolution
1. The fineness of detail in a reproduced spatial patter.
2. The degree to which system or a device distinguishes fineness of detail in a scanned or generated spatial
patter
3. The smallest increment of distance that can be read and acted on by a numerical control system
Resolver
A rotary feedback device which converts mechanical motion into analog electronic signals that represent motion
or position. See also encoder.
Retrofitting
The act of modifying or improving the design or construction of a piece of equipment in order to take advantage
of improvements in technology, For example the replacement of an outdated NC unit with a more modern CNC
Robot
An automatic device that performs functions ordinarily ascribed to human workers.
Page 229 of 234

ROM
Abbreviation for read only memory; an electronic memory module which is programmed with a special
programming device, making it impossible to modify the information stored on it.
RPM
Abbreviation for revolutions per minute.
Rapid
Positioning of the cutter near the work piece at a high rate of travel speed before the cut is started.
Register
An internal memory storage location for the recording of information.
Relative coordinates
Coordinates specified by difference in distance and/or angle measured from a previous set of coordinates rather
than from the origin point.
Reset
To return a register to zero or to a specified initial condition.
Right-hand rule
A method of determining the positive directions of the X-,Y-and Z-axes of a coordinate system and the positive
direction of rotation about an axis.
ROM
Abbreviation for read-only memory. The permanent memory of a computer that contains the computers most
fundamental operating instructions.
Scaling
The capability for altering axes dimensions by means of a given multiplication factor.
Scanner
Equipment to digitize coordinate values and store them in a data carrier. It is a device which traverses a
measuring sensor in order to collect and store those data which, after further processing, can result in tape
geometric data needed to control an NC machine.
Sensing Probe
High precision probe finger equipped with a contact switch system offering high reproducibility. Some types of
probes can be inserted into the spindle of a machine tool to perform measuring tasks both before and after
machining operations. They are also used for the identification of part position/orientation, and for quality
control purposes.
Sensitivity
The ratio of a change in steady-state output to a corresponding change of
input.
Sensor
A measuring probe or feeler which monitors technical procedures and determines values of pressure,
temperature, position, angle and so on.
Serial Data Input
Page 230 of 234

The transfer of information, in digital format serially bit by bit. Transfer speed (bits per second) is referred to as
baud rate; an alternative to parallel data input.
Serial-to-Analog Converter
Stores digital format signals transmitted in serial mode, and then converts them into analog signals.
Sequential Control
A positioning system in which movements occur sequentially along the various axes.
Sequence Number
A number identifying the relative position of a block of data.
Sequence Search
A program tape is advanced by means of a manual or programmed specific search command. While the search is
being performed the requested block number is displayed, and execution of intervening machine commands is
blocked.
Servomechanism
1. A feedback control system in which at least one of the system signals represents mechanical motion
2. An automatic control system incorporating feedback that governs the physical position of an element by
adjusting either the values of the coordinates of the values of their time derivatives.
3. A powerful amplifying device which takes an input signal from some
low-energy source and directs it to an output delivering much larger power. Power steering in automobiles
is an example.
Shaft Encoder (Rotary Encoder, Optical Encoder)
A device for converting analog data which are received in the form of angular position of a shaft into encoded
digital data
Silicon Controlled Rectifier (SCR) or Thyristor
An electronic device which is generally used in control systems for high-power loads such as electric heating
elements or direct current motors. Its operation is similar to a transistor.
Simulation
A mathematical logic model held in a computer which provides a means of studying the interactive effects of
variables in a complex system. It is not a system design optimization tol, but rather it provides answers to the
“what if” question.
Simultaneous Control
The simultaneous control of multiple axes.
Single Block Operation
Operational mode in which only one block a part program is executed. The execution of each subsequent block
must be individually started by the operator.
Skip
To ignore one or more instructions in an operational sequence.
Slash Code
A switch or signal input which can be used by the programmer to cause the NC unit to suppress all blocks which
begin with a slash character before the N address.
Page 231 of 234

Soft keys
Mechanical or electronic keys installed adjacent to the screen display of a CNC. There are usually between five
and eight, and their functions may be preset by the operator. Soft keys can replace over a hundred hardware
keys associated with fixed, discrete functions.
Software
Programs necessary for executing tasks with the hardware of a computer. In connection with CNC for example,
the software is the operating program for the built-in microprocessor or minicomputer. It basically determines
the specifications and capabilities of the control. Included are testing software, DNC software, postprocessor
software, and so on.
Soft-Wired NC
An NC whose features are specified by the software (that is, by the programs of a CNC computer) and not by the
Save
To store data on a disc or tape.
Screen
A video display tube or CRT that display graphical information.
Serial Interface
An electrical connection that permits the liking of computers and peripherals over long distance. Also called the
Rs-2332C interface.
Spindle Speed (code word)
A code containing the letter S followed by digits. This code determines the rpm or cutting speed of the cutting
spindle of the machine.
Stylus
An input device that looks lie a pen and is used like a digitizer puck.
Tool Function
A commend identifying a tool and calling for its selection. The address is normally a T word.
Tool Length Compensation
A register that eliminates the need for preset tooling. Allows the programmer to program all tools as if they are
of equal to length.
Tool Offset
A correction for the tool position parallel to a controlled axis.
Turnkey
A computer system sold complete and ready to use for a specific a applications. You just “turn the key”.
Unit
A User-defined distance, such as inches, meters and miles.
View
A Graphical representation of a two dimensional drawing or a three dimensional model from a specific location
(view point) in space.
Viewpoint
A location in three dimensional model space from which a model is viewed.

Page 232 of 234
Wire frame Model
A two-or-three dimensional representation of an object consisting of boundary lines or edges of an object .
Word
A command or combination of commands that stores information that the machine tool acts upon.
Word Address Format
The specific group of symbols in a block of information by one or more alphabetical characters which identify the
measuring of the word.
X Axis
Axis of motion that is always horizontal and parallel to the work holding surface.
Y Axis
Axis of motion that is perpendicular to both the X-and Z- axes.
Z Axis
Axis of motion that is always parallel to the principal spindle of the machine.
Page 233 of 234

19.0 Contact Details:
For Any service / support related queries, kindly note our contact details mentioned
below:
Hytech Educational Equipment
Web Support: http://www.hytecheducation.in/index.php#join_form
Email: support@hytecheducation.net / factory@hytecheducation.in /
sales@hytecheducation.com / info@hytecheducation.com
Phone: +91 83082 95100
Address:
Office:- 202A, Umashankar, Rambaug Colony, Paud Road, Pune 411 038
Factory:- Laygude Industial Estate, Lagamala, Sinhgad Road, PUNE 411041
Page 234 of 234

Manual Clt100 Slt100

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Clt100 Slt100

Uploaded by

Copyright:

Available Formats

HYTECH

1.0 INTRODUCTION ......................................................................................................................................................................................................... 7

8.2 PROGRAMING FORMATS ............................................................................................................................................................................... 70

10.2.9 Custom Control Conversion................................................................................................................................................ 109

Example 12 (G71): - ......................................................................................................................................................................................................... 154

16.4.2 Power supply ........................................................................................................................................................................................ 198

We have successfully developed and manufactured indigenous ‘Flexible Manufacturing

COME; JOIN US TO EXPERIENCE THE NEW EDGE IN CAD-CAM TECHNOLOGY.

1.1 PC Based Machines Vs. ‘Hytech’ PLC Based Machines

Comparison of PLC Based System and PC Based System:

Characteristics PLC Based System PC based system

Life Life of a PLC is around 10 to 15 years Life of a PC is around 2 to 3 years

Mode of Ethernet communication RS 232 / RS 485 Communication

I/O Capacity DI: 256, DO: 256 DI:32, DO:32

Maximum Input Speed 920 KHz 10KHz

Interpolation Up to 4 Axes simultaneous interpolation Simultaneous interpolation of more

1.2 AIM OF HYTECH CNC TRAINER

 Acquire basic knowledge of CAD and CAM

 To get familiar with basic operations of CNC Machines

 To understand theoretical as well as practical applications of CNC Machines

 Understand programming of CNC Machines

 Understand basic working principles of CNC Machines

 Understand programming language / nomenclature required for different popular

1.3 Basic Principle

Specifically, automatic machine tools are programmed to perform an ordered sequence of

1.4.1 Program Preparation Methods

 Programming in the planning department

 Programming in the workshop

 Computer assisted programming

 Higher level programming languages

1.4.1.1 Programming in the Planning Department

This method is advantageous where;

 The existing CNC systems are complicated

 The work pieces have complex geometry

 There are many similar CNC machines in the plant

 Workshop personnel are qualified.

 Programming systems can be utilized.

1.3.1.2 Workshop Programming

This programming can be used when

 The CNC machines are easy to operate

 The work pieces have similar geometry

 There are only a few CNC machine in the plant

 Rapid fault elimination and program optimization are essential.

1.4.1.3 Manual Programming

1.4.1.4 Computer Assisted Programming

Preparing NC programs for complicated parts with a programming language following

A pre-processor is software consisting of a specially structured set of symmetrical rules and

 Auxiliary statements, and

 Post processor statement.

1.5 Advantages of CNC Machines

- Elimination of operator errors

- Ease of doing complicated jobs

- Longer tool life

- Exact estimation of cycle time

- Less dependence on Skilled Labor

- Reduction in total rejection

1.6 Operational Safety

Improper operation or unauthorized uses may lead to a malfunction or an accident. Thus, if a

1.7 SAFETY PRECAUTIONS

- Finally, carry out the machining process on the raw material.

2.0 Technical Specifications

2.1 Model: SLT 100 Servo

SLT 100 Servo

Tailstock Quill Stroke 100 mm