Module-II

Manual Part Programming

A binary digit is called a bit.
In punched tape, the values 0 or 1 are represented by the absence or
presence of a hole in a certain row and column position
Out of one row of bits a character is formed.
A character is a combination of bits representing a numerical digit (0-9),
an alphabetical letter (A-Z),or a symbol.
Out of a sequence of characters, a word is formed.
A word specifies a detail about the operation, such as x-position, y-
position, feed rate, or spindle speed.
Out of a collection of words, a block is formed.
A block is one complete NC instruction.
It specifies the destination for the move, the speed and feed of the cutting
operation. and other commands that determine explicitly what the machine
tool will do
 Block Formats
Block Format Example

Fixed sequential format 00100070000300003

00200070000600003
Fixed sequential format with TAB 001 00 07000 03000 03
002 00 07000 06000 03
Tab sequential format 001 00 07000 03000 03
002 00 06000
Word address format N001G00X07000Y03000M03
N002Y06000
Word address format with TAB N001 G00 X07000 Y03000 M03
N002 Y06000
 Word Prefixes Used in Word Address Format
Word Examp Function
Prefix le
N N01 Sequence number; identifies block of Instruction.
G G21 Preparatory word; prepares controller for instructions given
in the block
X,Y,Z X75 Coordinate data for three linear axes
U, W U25 Coordinate data for incremental moves in turning in the x-
and z-directions respectively.
A, B, C A90 Coordinate data for three rotational axes.
R R100 Radius of arc; used in circular interpolation.
F F40 Feed rate per minute or per revolution
S S1000 Spindle rotation speed in revolutions per minute
T T14 Tool selection
D D05 Tool diameter
M M03 Miscellaneous command
 G-CODES
G Code Function
G00 Point-to-point movement (rapid traverse)
G01 linear interpolation movement.
G02 Circular interpolation clockwise
G03 Circular interpolation counter clockwise
G04 Dwell for a specified time
G17 Selection of x-y plane in milling.
G18 Selection of x-z plane in milling.
G19 Selection of y-z plane In milling
G20 Input values specified in inches
G21 Input values specified in millimetres
G28 Return to reference point.
 G-CODES
G Code Function
G32 Thread cutting in turning
G90 Programming in absolute coordinates
G91 Programming in incremental coordinates.
G94 Specify feed per minute in milling and drilling
G95 Specify feed per revolution in milling and drilling
G98 Specify feed per minute in turning
G99 Specify feed per revolution in turning
 M-CODES
M Code Function
M00 Program stop, used in middle of program
M02 End of program. Machine stop
M03 Start spindle in clockwise direction
M04 Start spindle in counter clockwise direction
M05 Spindle stop
M06 Execute tool change, either manually or automatically
M07 Turn cutting fluid on flood
M08 Turn cutting fluid on mist
M09 Turn cutting fluid off
M10 Automatic clamping of fixture, machine slides, etc.
 M-CODES

M Code Function
M17 Spindle and cutting fluid off
M19 Turn spindle off at oriented position
M30 End of program. Machine stop. Rewind tape
 Computer Assisted Part Programming

Manual part programming can be time consuming, subject to errors for

processing complex geometries or requiring many machining
operations
In computer assisted part programming, the machining instructions are
written in English-like statement that are translated by computer into
low level machine code that can be interpreted by the m/c tool
controller
Computer Assisted Part Programming
 Computer Assisted Part Programming

Two main tasks of the programmer are:

1. Defining the geometry of the work part
2. Specifying tool path and operation sequence
Defining part geometry
I. Any complicated/irregular work part composed of basic
geometric elements and mathematically
II. Any components that can be conceived by a designer can be
descried by point, straight lines, planes , circles, cylinder and
other mathematically defined surfaces
 Defining Part Geometry

Simplest way to define a point by means of its coordinates

P1= POINT/20,30,0
where point is identified by the symbol (P1), and its coordinates are
given in the order x ,y, z
Line can be defined
L1= LINE/P1,P2
Circle can be defined by its center location and radius
C1= CIRCLE/CENTER,P3,RADIUS,20
 Specifying Tool Path and Operation
Sequence

Tool path consist of a sequence of basic elements previously defined to

guide the cutter
E.g.. GOLFT/L1,TANTO,C1
Tool proceeds along surface of L1 until it is tangent to (TANTO) circle
C1
GOTO/P0
Go to a previously defined point P0
 Computers Tasks in Computer Assisted
Part Programming

The computers role in computer assisted part programming consist of the

following tasks
1. Input translation
2. Arithmetic and cutter offset computation
3. Editing
4. Post processing
 Computers Tasks in Computer Assisted
Part Programming

First three tasks are carried out under the supervision of language
processing program
Post processor requires a separate computer program
The part programmer enters the program using high level language
The input translation module converts the coded instructions contained
in the program into computer usable form
 Input Translation Module

Accomplishes the following tasks

Syntax check of the input code to identify error in format, statement
sequence
Assigning sequence number to each statement in the program
Converting geometry elements into suitable form for computer
processing
Generating an intermediate file called PROFIL that utilized in
subsequent arithmetic calculations
 Arithmetic Module
Consists of a set of subroutines to perform the mathematical
computations required to define part surface and generate tool path,
including compensation of cutter offset
The arithmetic computations are performed on PROFIL file
The output of this module is called CLFILE(cutter location file)
File consists mainly of tool path data
 Editing & Post Processing

Editing , the CLFILE a new file is generated called CLDATA

CLDATA provides readable data on cutter location and machine tool
operating commands
The m/c tool commands are converted to specific instructions during
post processing
During post processing CLDATA file are converted into low level
code that can be interpreted by NC controller for a specific m/c tool
 Programming with APT(Automatically
Programmed Tooling)

There are four basic types of statements in the APT language

1. Geometry statements, also called definition statements, are used to
define the geometry elements that comprise the part.
2. Motion commands are used to specify the tool path.
3. Postprocessor statements control the machine tool operation, for
example, to specify speeds and feeds, set tolerance values for circular
interpolation, and actuate other capabilities of the machine tool.
4. Auxiliary statements, a group of miscellaneous statements used to
name the part program, insert comments in the program and
accomplish similar functions.
 Geometry Statements
The geometry of the part must be defined to identify the surfaces and
features that are to be machined.
The general form of an APT geometry statement is:
SYMBOL = GEOMETRY TYPE/descriptive data
E.g.: P1= POINT/20,30,10
An APT geometry statement consists of three sections.
The first is the symbol used to identify the geometry element.
The second section of the APT geometry statement is an APT major
word that identifies the type of geometry element
The third section of the APT geometry statement provides the
descriptive data that define the element precisely
 Motion Commands
All APT motion statements follow a common format ,just as
geometric statements have their own format.
MOTION COMMAND/descriptive data
E.g.: GOTO/P0
The statement consists of two sections separated by a slash.
The first section is the basic command that indicates what move the
tool should make
The descriptive data following the slash tell the tool where to go
 Motion Commands
The part programmer keys into this starting position with the following
statement:
FROM/PTARG
where FROM is an APT vocabulary word indicating that this is the
initial point from which all others will be referenced; and PTARG is
the symbol assigned to the starting point.
For point-to-point motions, there are only two commands: GOTO and
GODLTA
GOTO statement instructs the tool to go to a particular point location
specified in the descriptive data.
The GODLTA command specifies an incremental move for the tool.
GODLTA/50, 120, 40
 Contouring Motion Commands

Contouring motion commands are more complicated than PTP

commands are because the tool's position must be continuously
controlled throughout the move
To exercise this control the tool is directed along two intersecting
surfaces until it reaches a third surface
These three surfaces have specific names in APT; they are:
1. Drive surface. This is the surface that guides the side of the cutter
2. Part Surface. This is the surface is a plane, on which the bottom or
nose of the tool is guided.
3. Check surface. This is the surface that stops the forward motion of
the tool in the execution of the current command
 Check Surfaces

There are several ways in which the check surface can be used.
This s is determined by using any of four APT modifier words in the
descriptive data of the motion statement
The four modifier words arc TO, ON, PAST. and TANTO.
Check Surfaces
Check Surfaces
 Motion Commands

TO- moves the tool into initial contact with the check surface
ON- positions the tool center on the check surface
PAST-moves the tool just beyond the check surface.
TANTO- moves the tool to the point of tangency between two surfaces
GOLFT -commands the tool to make a left turn relative to the last move.
GORGT- commands the tool to make a right turn relative to the last
move.
GOFWD- commands the tool to move forward relative to the last move.
GOBACK -commands the tool to reverse direction relative to the last
move.
GOUP- commands the tool to move upward relative to the last move
GODOWN- commands the tool to move down relative to the last move.
 Postprocessor Statements

Postprocessor statements control the operation of the machine tool and

play a supporting role in generating the tool path
Such statements are used to define cutter size, specify speeds and
feeds, turn coolant flow on and off, and control other features of the
particular machine tool on which the machining job will be performed
The general form of a postprocessor statement is:
POSTPROCESSOR COMMAND/descriptive data
 Postprocessor Statements
UNITS/MM- indicates that the specified units used in the program are
INCHES or MM
CUTTER/20- defines cutter diameter for tool path offset calculations;
the length and
other dimensions of the tool can also be specified
SPINDL/1000, CLW- specifies spindle rotation speed in revolutions
per minute. Either
CLW (clockwise) or CCLW (counter clockwise) can be specified
SPINDL/OFF - stops spindle rotation
FEDRAT / 40, IPM -specifies feed rate in millimetres per minute or
inches per minute.
Minor words IPM or IPR are used to indicate whether the feed rate is
units per minute or units per revolution of the cutter
 Postprocessor Statements

RAPID -engages rapid traverse (high feed rate) for next move(s)
COOLNT/FLOOD -turns Cutting fluid on
LOADTL/01- used with automatic tool changers to identify which
cutting tool should be loaded into the spindle
DELAY /30- temporarily stops the machine tool for a period specified
in seconds
 Auxiliary Statements

Auxiliary statements are used to identify the part program, specify

which postprocessor to use, insert remarks into the program, and so on
Auxiliary statements have no effect on the generation of tool path
PARTNO is the first statement in an APT program, used to identify
the program;
For example,
PARTNO SAMPLE PART NUMBER ONE
MACHIN 1-permits the part programmer to specify the postprocessor,
which in effect specifies the machine tool
 Auxiliary Statements

CLPRINT stands for "cutter location print," which is used to print out
the cutter location sequence
REMARK is used to insert explanatory comments into the program
that are not interpreted or processed by the APT processor
FINl indicates the end of an APT program
Postprocessor
 Postprocessor

The postprocessor is a computer program which is needed for every

MCU/machine-tool configuration
The postprocessor generates as output either the punched tape or information
which can be directly applied to prepare the tape by using some standard
peripheral equipment
The aid of computers in the preparation of punched tapes may be divided into two
stages
1. Using general processor, such as the APT programming system, which accepts
the programming statements and produce the instructions to guide the tool with
the appropriate machining parameters
2. An additional computer program, referred to as post processor, which accepts as
the input the general processor output, and generates as output either the
punched tape for a particular MCU/machine tool system
 Postprocessor

Post processor includes five principal elements: input, motion, auxiliary,

output and control
Input
Input elements reads the programming system output
Reading may be performed directly or with an input medium such as
punched card or magnetic tapes
The input element checks the input data for reliability and prints a list of
unprocessible information
 Postprocessor

Motion
The motion element performs all instructions concerned with the
tool movement
The motion element includes two functions usually denoted as the
geometry and dynamic portion
Geometric portion performs co-ordinate transformation into required
system
Geometric portion ensures that movement instructions to MCU will
not exceed the table size
Dynamic portion must prevent overshoots, undershoots, and other
dynamic effects related to the NC system structure
 Postprocessor

Auxiliary
The auxiliary element compares available preparatory and miscellaneous
functions of a specific NC configuration with the required functions which
are accepted from the input element
Output
The output element receives data from the motion and auxiliary elements
This data is converted into a format appropriate to be accepted by the
specific MCU
The output element generate the punched tape or an output in another
form that can be easily converted to punched tape
Control
The control element generates the timing of post processing, adapting all
elements and permitting program flow