Lesson Thirteen: Radius Compensation G40, G41, & G42

Radius Compensation G40, G41, & G42 (cutter radius

compensation for machining centers, tool nose radius compensation
for turning centers)
These features are commonly well covered in most basic CNC courses. However, basic
courses tend to stress how to use machining center cutter radius compensation in its
simplest form. And as experienced programmers know, you can be in for some surprises
when you apply it in more advanced applications. Here we introduce some rules not
commonly discussed in basic CNC courses and provide some suggestions for handling
the problems you can have.
Cutter radius compensation is one of the CNC machining center programmers most
helpful programming tools when it is properly applied. It keeps the programmer from
having to calculate the tools center line coordinates, it allows the easy specification of
roughing commands, and it allows a variety of cutter sizes to be used. If you work with
CNC machining centers, you have probably used this extremely helpful tool and know
these benefits first hand.
Yet there are many times when cutter radius compensation may not behave as expected.
If not correctly programmed, the control may cause odd motions or generate alarms. We
all dread cutter radius compensation alarms because they can be the most difficult alarms
to diagnose and correct. In some cases, the programmer may even be tempted to give up
on cutter radius compensation altogether and program centerline coordinates.
While programming centerline coordinates (without cutter radius compensation) is
sometimes the fastest way around a cutter radius compensation problem, it leaves the
programmer with a great deal of frustration. He or she will be hesitant to use cutter
radius compensation in the future. Because it can sometimes be frustrating to work with
this extremely useful tool, and because so many programmers give up on it prematurely,
we will give this lengthy presentation on how to handle problems with this important
control feature. This section will show you some of the reasons why you may have had
problems with cutter radius compensation in the past. You will also see how to avoid
problems with cutter radius compensation in the future.
The first point we want to make is this: There is nothing magical about how cutter
compensation behaves. There are logical and understandable rules that govern how cutter
compensation behaves for every CNC control. Though the rules may change slightly
based on the control manufacturer, every time cutter compensation behaves
unexpectedly, there is a logical reason and solution. If you understand the basic points
we make in this section, you should be able to solve most cutter radius compensation
problems. Your determination will be the key factor that determines how quickly you
can find and correct the problem.
The two ways to use offsets with cutter radius compensation
Before discussing possible cutter radius compensation problems, we will examine the two
ways by which the cutter radius compensation offset can be used. With one method, the
programmer generates the program using part surface coordinates in the program. This
method often times allows the programmer to use print dimensions, and is the method of
choice of most manual CNC programmers. In this case, the offset used with cutter radius
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Lesson Thirteen: Radius Compensation G40, G41, & G42

compensation represents the radius of the cutter for most CNC controls (though on some
controls, the diameter of the cutter input as the offset). For example, if using a one inch
diameter cutter, the offset will be 0.500 inch, since the radius or a one inch cutter is 0.500
in.
With the second method, the programmer uses the cutters centerline coordinates in the
program, and bases the programmed coordinates on a planned cutter size. In this case,
the tool offset will be the difference in radius from the planned cutter size to the actual
cutter size being used. For example, if the program were developed for a one inch
diameter cutter, all programmed dimensions would reflect the 0.500 radius of the tool,
and would be calculated accordingly. If a one inch diameter cutter is used during
machining, the offset value would be zero. If a one inch diameter cutter is not available,
the offset must reflect the difference in radius from the one inch planned cutter size to the
size actually being used. For example, if a 0.875 diameter cutter is actually used with the
program, the offset would be minus .0625 inch.
Generally speaking, fewer problems present themselves when the value of the tool offset
used with cutter radius compensation is kept small. This is evidenced by the fact that
almost all cutter radius compensation alarms will go away if the offset value is set to
zero. While this does not actually fix the problem, it does show that the cutter radius
compensation problem is related to the size of the offset. The second method of
assigning offsets reduces the possible problems that are encountered with cutter radius
compensation because the radius offset is kept smaller. For this reason, and since CAM
systems can generate cutter centerline coordinates as easily as workpiece surface
coordinates, many CAM system programmers prefer to have their CNC programs created
in this manner.
Since more problems occur when the offset used with cutter radius compensation is large,
all examples given in this section will be related to the first method of assigning offset
values, where the offset is the radius of the cutter. However, if you use the second
method of assigning offsets (programming cutter center line coordinates), the same basic
rules will apply when you have problems.
How cutter radius compensation works
Understanding how your CNC control interprets cutter radius compensation commands
will be your first step in solving any cutter radius compensation problem. Though there
are some minor differences related to how each control manufacturer internally handles
cutter radius compensation, the basic points we make in this section will apply to most
current CNC controls.
Using cutter radius compensation involves three basic programming steps.
1) Instate cutter radius compensation
2) Make movements to machine workpiece
3) Cancel cutter radius compensation
Cutter radius compensation is instated with a command that tells the control how to
position the cutter relative to the surfaces being machined throughout its movements.
Either the cutter will be positioned to the left of the surface (with a G41) or to the right of
the surface (with a G42). You can easily remember G41 and G42 if you know the

Lesson Thirteen: Radius Compensation G40, G41, & G42

difference between climb milling and conventional milling. If using a right hand cutter
(spindle rotating clockwise with M03), climb milling is instated with G41 and
conventional milling is instated with G42.
Once instated, the control will keep the cutter to the left or right side of a series of lines
and circles generated with straight line (G01) and circular (G02 and G03) commands.
These lines and circles represent the actual surfaces being machined.
Cutter radius compensation will remain in effect until cancelled. That is, the cutter will
be kept on the left side or right side of all motion commands until this cancellation. The
command to cancel cutter radius compensation is G40.
To begin to solve any cutter radius compensation problem, you must first be able to
visualize what is really happening while the cutter is making its movements around the
surfaces being machined. As stated, the surfaces programmed are a series of lines and
circles commanded by G01, G02, and G03 (and even G00).
The next drawing shows the motions during a series of motion commands under the
influence of cutter radius compensation. As you can see, each movement the control
generates after cutter radius compensation is instated is based on the condition of how
cutter radius compensation was instated (right or left), the size of the milling cutter (in the
offset), and the coordinates used in the program. In this example, the control is being
told to keep the cutter on the left side of all programmed surfaces. The motions will be
adjusted automatically. For example, in the movement to point number two, the control
cuts short the motion by a value equal to the radius of the cutter. In the motion to point
number three, the control lengthens the motion by the radius of the cutter, and so on.

Lesson Thirteen: Radius Compensation G40, G41, & G42

Drawing shows motions under the influence of cutter radius compensation

Though this drawing only illustrates straight line motions (G01), the same is true for
circular motions. Also, the motions in the previous drawing are quite simple, just a series
of straight line motions, each moving along only one axis. The next drawing shows that a
CNC control can just as easily compensate for the radius of the cutter even with more
complex shapes involving angular and circular motions. Notice how precisely the control
can generate tangency points between angular and circular movements. Indeed, this is
one of the main reasons for using cutter radius compensation in the first place.

Lesson Thirteen: Radius Compensation G40, G41, & G42

Drawing shows how cutter radius compensation works for more complicated motions

Almost all cutter radius compensation problems stem from one of two possible causes.
Either the control is unable to drive the cutter through your defined motions without
violating the workpiece, or the motions commanded in the program are not possible.
When either of these two problems is encountered, one of two things will happen. Either
the control will generate an alarm, stopping the programs execution, or the actual
motions generated by the program will not be as desired (probably scrapping a
workpiece). Lets start by looking at those problems that generate alarms.
Alarms and possible causes
Most CNC controls handle cutter radius compensation problems with only a few cryptic
alarms. That is, most controls do very little to help you diagnose cutter radius
compensation problems. They may show you the general area of the program that is
generating the alarm, but most will not even specify which command is actually causing
the problem. The most common catch all alarm is the over-cutting will occur alarm.
Diagnosing the over-cutting alarm
This is the most common alarm you will receive when working with cutter radius
compensation. While the actual wording for this alarm varies from one control to the
next, here is a common definition: Over-cutting will occur during cutter radius
compensation. This alarm is generated from more than one possible cause. Because
this alarm can be generated from a variety of problems, it is also the most difficult cutter
radius compensation alarm to diagnose.
Whenever you receive this alarm, the control is trying to tell you that the cutter will
violate the programmed path (and usually the workpiece) if the program is allowed to

Lesson Thirteen: Radius Compensation G40, G41, & G42

run. However, it will not point you in any direction that will help you fix the problem or
even tell you how the surface is being violated. For this reason, and since it could be the
result of several problems, it is one of the most feared alarms a CNC control can
generate. We sympathize with this dreadful feeling.
As stated, there are several conditions that will cause this alarm. If you know them, you
will be much better prepared to diagnose your specific problem. Most have to do with the
size of the tool offset value as it relates to the surfaces being machined.
Insufficient clearance for the cutter at the starting position
Almost all CNC controls require that the cutter be at least the tool radius away from the
surface you will be milling before you instate cutter radius compensation. The next
drawing shows this relationship. To send the tool to its approach position, centerline
coordinates must be used. In this example, the value in the tool offset must not exceed
.600 inch (1.200 diameter cutter). If it does, most controls will generate the over-cutting
alarm. If you receive the over-cutting alarm early on in the cutters motion, this would be
the first thing to check.

Drawing shows the relationship of the cutter with the workpiece at the cutters start point

Offset value is too large

All programs using cutter radius compensation will have limitations as to how large the
cutter can be. As the cutter size grows, the control will have to keep the generated
centerline coordinates for the cutter farther and farther away from the surfaces to be
machined. Depending on the contour, there may be times when the compensated motion
along one surface will actually violate another. If this happens, the control will generate

Lesson Thirteen: Radius Compensation G40, G41, & G42

the over-cutting alarm before the violating motion occurs. The next drawing
demonstrates this. Notice that this is the same series of motions shown in a previous
example, but this time the cutter size has been increased. It may not be apparent to the
programmer (or operator) at the time the offset is entered that the tool to be used is be too
large to fit into the recess of this part. In this case, the over-cutting alarm would occur.

Drawing illustrates that the cutter is too large to fit into the recess.

This can be the hardest kind of cutter radius compensation problem to find for two
reasons. First, the blueprint can sometimes be very deceiving if it is not to scale. For this
reason, as you attempt to solve any cutter radius compensation problem, it helps to ignore
the blueprint and use only the programmed coordinates as your way of viewing the
motions. If viewing the blueprint, you may be tempted to make certain assumptions
about the correctness of your programmed coordinates. If you put the blueprint aside and
plot coordinates to scale from the program, many times you will see a basic mistake
related to this form of over-cutting problem. You can use techniques similar to the
drawing shown in the previous illustration, actually drawing in the exact cutter size being
used.
Second, since the program will behave properly if the offset is small enough to allow the
programmed motion, this over-cutting problem may not present itself the first time the
program is run. It is possible for the program to have been run several times, then the
operator may change cutter sizes (to a larger cutter) and then the over-cutting problem
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Lesson Thirteen: Radius Compensation G40, G41, & G42

occurs. Say, for example, the operator is using a 1 in diameter end mill to mill a surface
generated with cutter radius compensation. After several workpieces, the cutter becomes
dull and has to be replaced. However, the operator finds that there are no more 1 in end
mills left in stock, so a 1.25 diameter end mill is used instead. When the offset is
changed to that needed for the 1.25 diameter end mill, an over-cutting alarm may be
generated since an over-cutting problem may now crop up somewhere along the contour
that did not occur with the smaller 1 in end mill. Note that these problems can be
eliminated if the programmer specifies the maximum cutter size on the setup sheet.
Attempting to machine multiple contours under the influence of cutter radius
compensation
The biggest cutter radius compensation problem for beginners seems to be telling how
much can be done with cutter radius compensation during one series of motions. You
must remember that cutter radius compensation remains in effect until cancelled. This
means the control will continue to keep the tool on the left side or right side of all
motions, once cutter radius compensation is instated. Beginners have the tendency to
instate cutter radius compensation one time and then try to machine several separate
contours without concern for the (rapid) motions from one contour to the next. While
moving from one contour to the next, the control will remain under the influence of cutter
radius compensation and try to compensate cutter motions accordingly. While there are
times when this will work (only by coincidence or cautious planning), in most cases the
motions between contours will cause the over-cutting alarm. Even if no alarm is
generated, unless the programmer planned each motion carefully, the motions the control
makes from one contour to the next will probably be incorrect.
When machining multiple contours, you must instate cutter radius compensation,
machine with it, and finally, cancel it. Then go on to the next contour. Instate, machine,
cancel. This must be repeated for each of the contours to be machined.
By contour, we mean a series of motions while the cutter remains in contact with the
work. Of course, several commands could make up one contour. However, if you have to
rapid in X and Y to begin machining again, you must consider the next series of cutting
motions as a separate contour.
It can sometimes be difficult to keep instating cutter radius compensation for every
contour if there are many contours to be machined. But to reap the benefits of cutter
radius compensation, you must adhere to its rules.
Forgetting to cancel cutter radius compensation
Once instated, cutter radius compensation must be cancelled. One common cause for the
over-cutting alarm is forgetting to cancel cutter radius compensation. Because the
control is still under the influence of cutter radius compensation, the subsequent motions
after the contour is machined should eventually cause this alarm. However, we must
warn you here. If the subsequent motions do not break the rules of cutter radius
compensation (only by shear coincidence), it is possible that the next tool (maybe a drill)
will make motions still under the influence of the last tools cutter radius compensation.
In this case, some very strange looking things can happen. If the next tool is a drill (or
any hole machining tool), the tool will not go to the correct coordinates to machine the
hole. This can be a very difficult problem to diagnose. In this case, you will be looking

Lesson Thirteen: Radius Compensation G40, G41, & G42

for the problem in the drills of commands. You may not see that the problem is in the
previous tool!
Maximum cutter size exceeded alarm
The second common alarm with cutter radius compensation is related to the maximum
cutter diameter possible with inside radii. Though the wording varies from one control to
the next, here is one popular definition: Cutter diameter tool large for inside radius.
This alarm has to do with circular commands when machining an inside radius. For
inside radii, the cutter radius compensation offset value must be smaller than or equal to
the radius to be machined. The next drawing shows an example. In this case, the
maximum cutter size would be one inch in diameter.

Drawing illustrates that cutter radius must be smaller than smallest inside radius

Other limitations of cutter radius compensation

Unfortunately, there are other times when cutter radius compensation can behave poorly.
In some cases, no alarm is generated, but the motions are not correct. The control may be
doing its best to interpret what you want, but its interpretation of what you want does not
match your actual requirement. Because the control is not generating any alarm, and
because the amount of error in generated motion may be very small, it can be hard to
detect this kind of problem until after a workpiece is machined. For this reason, this can
be the hardest kind of cutter radius compensation problems to find and diagnose. Here
are some things to watch for when using cutter radius compensation that may cause this
kind of problem.

Lesson Thirteen: Radius Compensation G40, G41, & G42

Two moves in the same direction
With most CNC controls, there is a severe limitation with regard to change in motion
direction. In order to compensate correctly, the CNC control requires that some
detectable change in motion direction occurs from one command to the next. That is, two
consecutive motions in the same direction are not allowed. This can be frustrating, since
there are times when this kind of motion is necessary. For example, say youre machining
a weldment. When the tool comes close to the weld flash (the joint of the weld itself),
you may want to slow the feed and speed, then continue machining the flash area. (The
weld area is usually much harder than the workpiece material if the part has not been
annealed.) Once the weld flash area was cleared, you would want to increase the feed
and speed to their original values and continue. These three motions could all occur along
the same motion direction. With most CNC controls, the easiest way around the problem
is to program centerline coordinates (not using cutter radius compensation).
Unfortunately, if you must use cutter radius compensation, on most controls, no change
in speed and feed will be allowed since it will not be possible to make two consecutive
movements in the same direction.
Note that some CNC controls allow something called directional vectors to be
programmed within a cutter radius compensation commands. With directional vectors,
the programmer is allowed to point in the direction of the next movement within the
current command. If your control allows directional vectors (usually P and Q words),
two consecutive moves in the same direction are easily possible.
Non-motion commands during cutter radius compensation
A CNC control is constantly looking ahead in the program to see what kind of motion is
coming up next. For cutter radius compensation, this look ahead feature allows the
control to select the ending point of the current command based upon what it sees in the
next command. The ending point for the current command will be different, based on
whether an inside intersection, outside intersection, or tangency is coming up relative to
the next command.
Every CNC control has a limited look ahead feature. The look ahead buffer (especially
for older controls) may be quite small. If non-motion data like feeds and speeds are
programmed during cutter radius compensation, the look ahead buffer can become filled
with non-pertinent data, and the control will not be able to calculate the end point of the
current command correctly. What will happen in this case can be difficult to predict.
While some controls will generate an alarm, others will do their best to determine what
you want, but motions may not be as desired. For this reason, we recommend keeping
unrelated commands away from cutter radius compensation movements.
Angles under 90 degrees
Some CNC controls (especially older controls) do not allow angles of under 90 degrees to
be programmed. With this type of control, if you attempt to command a movement
forming an angle under 90 degrees (forming an inside or outside surface) while under the
influence of cutter radius compensation, an alarm will be generated. Current CNC
controls have no limitation related to the size of an angle that can be generated.

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Lesson Thirteen: Radius Compensation G40, G41, & G42

Reversal in motion direction
There are times when you will be deceived during programming motions under the
influence of cutter radius compensation. Look at the next drawing. Notice that the slot in
this workpiece is the same width as the cutter diameter. You might think that as you
make the movement commands around this part, you could simply move to point three
and immediately back to point two. But reversing motion direction will not provide you
the motions you desire.

Drawing shows a time when you may be tempted to program a reversal in motion directions

Since the control will be keeping the tool on the right side of the surface programmed (in
this case), the workpiece will be badly violated, yet no alarm would occur.

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Lesson Thirteen: Radius Compensation G40, G41, & G42

Drawing shows what happens when you program a reversal of motion direction under the
influence of cutter radius compensation

In this case, the programmer would need to program the motions around the contour of
the slot. As long as the cutter is equal to or smaller than the slot width, the program will
execute properly, generating the desired cutter path.
Hints on how to cancel cutter radius compensation
After all cutting motions are completed, you must cancel cutter radius compensation with
a G40 command. However, there are times when your last cutting motion may leave the
cutter in a condition that makes you prone to making an error during the cancellation
command. The next drawing shows a series of motions generated by the program to
follow.

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Lesson Thirteen: Radius Compensation G40, G41, & G42

Drawing for example program

Program:
O0020 (Program Number)
N005 G54 G90 S350 M03 (Select coordinate system, turn spindle on CW at
350 RPM)
N010 G00 X0 Y2.2 (Rapid to point 7)
N015 G43 H01 Z.1 (Rapid down to just above work surface)
N020 G01 Z-.5 (Fast feed to work surface)
N025 G41 D32 Y1.5 F5.0 (Feed to point 6)
N030 X1.299 Y.75 (Feed to point 1)
N035 Y-.75 (Feed to point 2)
N040 X0 Y-1.5 (Feed to point 3)
N045 X-1.299 Y-.75 (Feed to point 4)
N050 Y.75 (Feed to point 5)
N055 X0 Y1.5 (Feed to point 6)
N060 Y2.2 (Feed to point 7)
N065 G40 (Cancel cutter radius compensation)
N070 G91 G28 Z0 (Return to reference position in Z)
N075 G91 G28 X0 Y0 (Return to reference position in X-Y)
N080 M30 (End of program)

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Lesson Thirteen: Radius Compensation G40, G41, & G42

Notice how the last motion of the program under the influence of cutter radius
compensation (movement to point 7) is a clearance movement away from the workpiece.
But since the motion is still under the influence of cutter radius compensation
(compensation is not cancelled until line N065), the tool will continue to stay on the left
side of the surface and the workpiece will not be machined correctly. There is still stock
to be removed on the last surface machined, as the drawing shows.
This kind of problem can be very difficult to foresee as you prepare to write the program.
Many programmers will be deceived, preparing the program as we have shown. Since
this kind of problem will not be obvious even during a dry run, only once a workpiece
has been machined (and possibly scrapped) will this kind of problem present itself.
To correct this problem you must understand how the control will interpret a cancellation
command (G40) within a straight line motion command. When the control sees the G40
within a G01 motion command, most will bring the cutters centerline to the line
generated by the canceling G01 motion as part of the last machining motion before the
cancellation command is executed. This is hard to visualize, so the next drawing shows
the motions generated by the corrected program to follow.

Drawing for example program to follow

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Lesson Thirteen: Radius Compensation G40, G41, & G42

Program:
O0021 (Program Number)
N005 G54 G90 S350 M03 (Select coordinate system, turn spindle on CW at
350 RPM)
N010 G00 X0 Y2.2 (Rapid to point 7)
N015 G43 H01 Z.1 (Rapid down to just above work surface)
N020 G01 Z-.5 (Fast feed to work surface)
N025 G41 D32 Y1.5 F5.0 (Feed to point 6)
N030 X1.299 Y.75 (Feed to point 1)
N035 Y-.75 (Feed to point 2)
N040 X0 Y-1.5 (Feed to point 3)
N045 X-1.299 Y-.75 (Feed to point 4)
N050 Y.75 (Feed to point 5)
N055 X0 Y1.5 (Feed to point 6)
N060 G40 Y2.2 (Cancel compensation during feed move to point 7)
N065 G91 G28 Z0 (Return to reference position in Z)
N070 G91 G28 X0 Y0 (Return to reference position in X-Y)
N075 M30 (End of program)
Notice in line N060, that the G40 command is now included with the movement to point
7. This time as the control looks ahead to line N060 (during the angular move in line
N055), it will see the cancellation command (G40) within the next motion command. For
this reason, the control will continue to bring the cutter along the angular motion
commanded by line N055 until its centerline is precisely on the (vertical) line generated
by N060, in effect canceling the compensation for the X axis. During the actual motion in
line N060, the cutter center will move to Y2.2, and finalize the cancellation of cutter
radius compensation.
As stated, this is difficult to visualize, especially before the program is actually running at
the machine. But this kind of cancellation problem is a common one and one you will
have to be prepared to deal with.
While we could not hope to prepare you for every possible problem you could ever
encounter with cutter radius compensation, the problem areas we have discussed should
point you in the right direction for those times when problems arise. If you come across
problems with cutter radius compensation that you cannot seem to solve, we encourage
you to stick with it until you find the reason why cutter radius compensation is behaving
poorly. If you are too quick to give up and go back to programming centerline
coordinates, you will never truly master this very helpful and powerful feature.
Do you really need control based tool nose radius compensation?
Many of the reasons for using cutter radius compensation on machining centers are not
applicable to turning center tool nose radius compensation. For example, one of the most
important reasons for using cutter radius compensation is to allow for a range of cutter
sizes. If the setup person doesnt have a milling cutter of the specified diameter, they can
use the cutter they do have, simply entering the correct value in the cutter radius
compensation offset. With turning center tool nose radius compensation, however, the

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Lesson Thirteen: Radius Compensation G40, G41, & G42

programmer normally specifies the exact size of the required tool nose radius and the
setup person must use a tool with precisely this radius.
Also, it is cutter radius compensation on machining centers that that is used for trial
machining and sizing with contour milling operations. If the contour isnt coming out
correctly, the cutter radius compensation offset can be changed. With turning center tool
nose radius compensation, by comparison, another form of offsets (commonly wear
offsets) is used to trial machine and hold size. For the most part, tool nose radius
compensation is uninvolved.
About the only reason for really needing tool nose radius compensation is to keep the
tangency point of the cutting tool perfectly flush with the (chamfered, tapered, and
radius) surfaces being machined. While this is extremely important, many programmers
that use computer aided manufacturing (CAM) systems eliminate the need for control
based tool nose radius compensation (G41 and G42) by specifying that the CAM system
output the tool path based upon the required tool nose radius. In essence, the CAM
system is performing the tool nose radius compensation. This eliminates any problems
you can have with tool nose radius compensation (like those discussed for cutter radius
compensation) and keeps the setup person from having to enter tool nose radius
compensation values in the offset table. (If you do use G41 and G42, see the discussion
of the G10 command to learn how to program the offset entries for tool nose radius
compensation.)
Machining on both sides of button tool
One important exception exists to the previous discussion. If you are using are
machining using both sides of the cutting tools radius, as is commonly done with button
tools, you will be able to manipulate workpiece size by modifying the tool nose radius
compensation value in the offset. The next drawing shows an example.

Drawing shows an example of when tool nose radius compensation can be used to help hold size

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Lesson Thirteen: Radius Compensation G40, G41, & G42

Note that with the vast majority of turning operations, the tool will be machining only on
its leading edge. For these operations, wear offsets are used to manipulate the size the
cutting tool machines.

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