CNC Part Programming

(1) Programming fundamentals

Machining involves an important aspect of relative movement between cutting tool
and workpiece. In machine tools this is accomplished by either moving the tool with
respect to workpiece or vice versa. In order to define relative motion of two objects,
reference directions are required to be defined. These reference directions depend on
type of machine tool and are defined by considering an imaginary coordinate system on
the machine tool. A program defining motion of tool / workpiece in this coordinate
system is known as a part program. Lathe and Milling machines are taken for case
study but other machine tools like CNC grinding, CNC Hobbing, CNC filament winding
machine, etc. can also be dealt with in the same manner.
(1.1) Reference Points
Part programming requires establishment of some reference points. Three
reference points are either set by manufacturer or user.
a) Machine Origin
The machine origin is a fixed point set by the machine tool builder. Usually it cannot be
changed. Any tool movement is measured from this point. The controller always
remembers tool distance from the machine origin.
b) Program Origin
It is also called home position of the tool. Program origin is point from where the tool
starts for its motion while executing a program and returns back at the end of the cycle.
This can be any point within the workspace of the tool which is sufficiently away from
the part. In case of CNC lathe it is a point where tool change is carried out.
c) Part Origin
The part origin can be set at any point inside the machine's electronic grid system.
Establishing the part origin is also known as zero shift, work shift, floating zero or
datum. Usually part origin needs to be defined for each new setup. Zero shifting allows
the relocation of the part. Sometimes the part accuracy is affected by the location of the
part origin. Figure 29.1 and 29.2 shows the reference points on a lathe and milling
machine.

Figure 29.1. Reference points and axis on a lathe

Figure 29.2. Reference points and axis on a Milling Machine

(1.2 ) Axis Designation

An object in space can have six degrees of freedom with respect to an imaginary
Cartesian coordinate system. Three of them are liner movements and
other three are rotary. Machining of simple part does not require all degrees of freedom.
With the increase in degrees of freedom, complexity of hardware and programming
increases.Number
of
degree
of
freedom
defines
axis
of
machine.
Axes
interpolation
means
simultaneous
movement
of
two
or
more
different
axes
to
generate
required
contour.
For typical lathe machine degree of freedom is 2 and so it called 2 axis machines.

For typical milling machine degree of freedom is

, which means that two axes can
be interpolated at a time and third remains independent. Typical direction for the lathe
and milling machine is as shown in figure 12 and figure 13.
(1.3 ) Setting up of Origin
In case of CNC machine tool rotation of the reference axis is not possible. Origin can
set by selecting three reference planes X, Y and Z. Planes can be set by touching tool
on the surfaces of the workpiece and setting that surfaces as X=x, Y=y and Z=z.
(1.4 ) Coding Systems
The programmer and the operator must use a coding system to represent information,
which the controller can interpret and execute. A frequently used coding system is the
Binary-Coded Decimal or BCD system. This system is also known as the EIA Code set
because it was developed by Electronics Industries Association. The newer coding
system is ASCII and it has become the ISO code set because of its wide acceptance.
(2) CNC Code Syntax
The CNC machine uses a set of rules to enter, edit, receive and output data. These
rules are known as CNC Syntax, Programming format, or tape format. The format
specifies the order and arrangement of information entered. This is an area where
controls differ widely. There are rules for the maximum and minimum numerical values
and word lengths and can be entered, and the arrangement of the characters and word
is important. The most common CNC format is the word address format and the other
two formats are fixed sequential block address format and tab sequential format, which
are obsolete. The instruction block consists of one or more words. A word consists of an
address followed by numerals. For the address, one of the letters from A to Z is used.
The address defines the meaning of the number that follows. In other words, the
address determines what the number stands for. For example it may be an instruction
to move the tool along the X axis, or to select a particular tool.

Most controllers allow suppressing the leading zeros when entering data. This is known
as leading zero suppression. When this method is used, the machine control reads the

numbers from right to left, allowing the zeros to the left of the significant digit to be
omitted. Some controls allow entering data without using the trailing zeros.
Consequently it is called trailing zero suppression. The machine control reads from left
to right, and zeros to the right of the significant digit may be omitted.
(3) Types of CNC codes
(3.1) Preparatory codes
The term "preparatory" in NC means that it "prepares" the control system to be ready
for implementing the information that follows in the next block of instructions.
A preparatory function is designated in a program by the word address G followed by
two digits. Preparatory functions are also called G-codes and they specify the control
mode of the operation.
(3.2) Miscellaneous codes
Miscellaneous functions use the address letter M followed by two digits. They perform a
group of instructions such as coolant on/off, spindle on/off, tool change, program stop,
or program end. They are often referred to as machine functions or M-functions. Some
of the M codes are given below.
M00 Unconditional stop
M02 End of program
In principle, allM03
codes
are either
modal or non-modal. Modal code stays in effect until
Spindle
clockwise
cancelled by another
code counterclockwise
in the same group. The control remembers modal codes.
M04 Spindle
This gives theM05
programmer
an opportunity to save programming time. Non-modal
Spindle stop
code stays inM06
effectTool
only
for the(see
blockNote
in which
it is programmed. Afterwards, its function
change
below)
is turned off automatically.
For
instance
G04
is
a non-modal code to program a dwell.
M30 End of program
After one second, which is say, the programmed dwell time in one particular case, this
function is cancelled. To perform dwell in the next blocks, this code has to be
reprogrammed. The control does not memorize the non-modal code, so it is called as
one shot codes. One-shot commands are non-modal. Commands known as "canned
cycles" (a controller's internal set of preprogrammed subroutines for generating
commonly machined features such as internal pockets and drilled holes) are non-modal
and only function during the call.
On some older controllers, cutter positioning (axis) commands (e.g., G00, G01, G02,
G03, & G04) are non-modal requiring a new positioning command to be entered each
time the cutter (or axis) is moved to another location.
Command
group

Gcode

Function and Command

Statement

Illustration

Tool motion

G00

Rapid traverse
G00 Xx Yy Zz

G01

Linear interpolation
G01 Xx Yy Zz Ff

Circular Interpolation in
clock-wise direction
G02 G02 Xx Yy Ii Jj
G02 Xx Zz Ii Kk
G02 Yy Zz Jj Kk

Circular interpolation in
counter- clockwise
direction
G03 Xx Yy Ii Jj
G03 Xx Zz Ii Kk
G03 G03 Yy Zz Jj Kk

G17

Plane
Selection

G18

XY - Plane selection

ZX - Plane selection

YZ - plane selection
G19

G20
or
G70

Inch unit selection

Unit
Selection
G21
or
G71
Metric unit selection

G40

Offset
and
G41
compensatio
n

Cutter diameter
compensation
cancel

Cutter diameter
cancellation left

Cutter diameter
compensation
right
G42

Tool
motion
G00

G01

Rapid traverse
G00 Xx Zz

Linear interpolation
G01 Xx Zz

G02

Circular Interpolation in
clock-wise direction
G02 Xx Zz Ii Kk
(or)
G02 Xx Zz Rr

G03

Circular interpolation in
counter- clockwise
direction
G03 Xx Zz Ii Kk
(or)
G03 Yy Zz Rr

Illustrative Example Program

A contour illustrated in figure 29.3 is to be machined using a CNC milling machine. The
details of the codes and programs used are given below.
Example:

Figure 29.3 An illustrative example

O5678
N02 G21
N03 M03 S1000
N04 G00 X0 Y0

Program number
Metric programming
Spindle start clockwise with 1000rpm
Rapid motion towards (0,0)

N05 G00 Z-10.0

N06 G01 X50.0
N07 G01 Y20.0
N08 G02 X25.0 Y45.0 R25.0
N09 G03 X-25.0 Y45.0 R25.0
N10 G02 X-50.0 Y20.0 R25.0
N11 G01 Y0.0
N12 G01 X0.0
N13 G00 Z10.0
N14 M05 M09

Rapid motion towards Z=-10 plane

Linear interpolation
Linear interpolation
Circular interpolation clockwise(cw)
Circular interpolation counter clockwise(ccw)
Circular interpolation clockwise(cw)
Linear interpolation
Linear interpolation
Rapid motion towards Z=10 plane
Spindle stop and program end

CNC Part Programming II

In the previous section, fundamentals of programming as well basic motion commands
for milling and turning have been discussed. This section gives an overview of G codes
used for changing the programming mode, applying transformations etc.,
30.1 Programming modes
Programming mode should be specified when it needs to be changed from absolute to
incremental and vice versa. There are two programming modes, absolute and
incremental and is discussed below.
30.1.1 Absolute programming (G90)
In absolute programming, all measurements are made from the part origin established
by the programmer and set up by the operator. Any programmed coordinate has the
absolute value in respect to the absolute coordinate system zero point. The machine
control uses the part origin as the reference point in order to position the tool during
program execution (Figure 30.1).

30.1.2 Relative programming (G91)

In incremental programming, the tool movement is measured from the last tool position.

The programmed movement is based on the change in position between two

successive points. The coordinate value is always incremented according to the
preceding tool location. The programmer enters the relative distance between current
location and the next point ( Figure 30.2).

30.2 Spindle control

The spindle speed is programmed by the letter 'S' followed by four digit number, such as S1000. There
are two ways to define speed.
1. Revolutions per minute (RPM)
2. Constant surface speed
The spindle speed in revolutions per minute is also known as constant rpm or direct rpm. The change
in tool position does not affect the rpm commanded. It means that the spindle RPM will remain constant
until another RPM is programmed. Constant surface speed is almost exclusively used on lathes. The
RPM changes according to diameter being cut. The smaller the diameter, the more RPM is achieved;
the bigger the diameter, the less RPM is commanded. This is changed automatically by the machine
speed control unit while the tool is changing positions. This is the reason that, this spindle speed mode
is known as diameter speed.
30.3 Loops and Unconditional jump (G25)
The unconditional jump is used to repeat a set of statements a number of times.
Example: N10

In the above example, the program statements from N70 to N100 are repeated once when the
statement N160 is executed. Usually the G25 is used after a mirror statement. Illustrative example
geometry and its program are given below (Figure 30.3).
Example:

Fig. 30.3 Illustrative example for programming loops

30.4 Mirroring
The mirroring command is used when features of components shares symmetry about one or more axes
and are also dimensionally identical. By using this code components can be machined using a single set
of data and length of programs can be reduced.
G10 cancellation of mirroring image
G11 Mirror image on X axis
G12 Mirror image on Y axis
G13 Mirror image on Z axis
Example:

Fig. 30.4 Illustrative Example for mirroring

30.5 Shifting origin

G92 code is used to temporarily shift the origin to the reference point specified.

Example: G92 X-100 Y-80

In the above statement the x and y values gives the present values of original origin after shifting it. This
is illustrated through an example (Figure 30.5).
Example:

Fig. 30.5 Illustrative Example for shifting origin

Scaling
Scaling function is used to program geometrically similar components with varying
sizes.
Syntax: G72 Kk, where k is the scaling factor.
The scaling command can be cancelled by using the statement G72 K1.0.
Example:

Fig. 30.6 Illustrative Example for scaling

30.7 Pattern rotation

Pattern rotation is used to obtain a pattern of similar features. G73 code is used to
rotate the feature to form a pattern.
Syntax G73 Aa, where 'a' is the angle of rotation. This command is cumulative, and the
angle gets added up on time the program is executed. So all the rotational angle
parameters should be cancelled using the code G73.
The unconditional jump code G25 is used in conjunction with this code to achieve the
desired rotation.

The following example (Figure 30.7) depicts the case of a pattern which needs to be
programmed through G73.
Example:

Fig. 30.7 Illustrative Example for Pattern rotation

30.8 Tool selection

Tool selection is accomplished using 'T' function followed by a four digit number where,

first two digits are used to call the particular tool and last two digits are used to
represent tool offset in the program. The tool offset is used to correct the values entered
in the coordinate system preset block. This can be done quickly on the machine without
actually changing the values in the program.
Using the tool offsets, it is easy to set up the tools and to make adjustments
Feed rate control
Cutting operations may be programmed using two basic feed rate modes:
1. Feed rate per spindle revolution
2. Feed rate per time
The feed rate per spindle revolution depends on the RPM programmed.