COMPUTER INTEGRATED MANUFACTURING

LAB MANUAL

SUBJECT SUPERVISOR:
LAB INCHARGE: Dr. A.K MADAN
Sandeep sir (Associate Professor)

DEPARTMENT OF MECHANICAL ENGINEERING

DELHI TECHNOLOGICAL UNIVERSITY
(Formerly Delhi College of Engineering)
Bawana Road, Delhi-110042
 EXPERIMENT NO-1

AIM: - To Study NC, CNC, DNC Machine tools in CIM

THEORY:
NC (Numerical Control)

It can be defined as a form of progressive automation in which process is controlled by

numbers, letters and symbols. In NC, the number forms programs of instructions.Basically a
NC machine runs on a program fed to it,which consists of precise instructions about the
methodology of manufacture as well as movements.
Numerical control should be considered as a possible mode of controlling the operation for any
production situation possessing the following characteristics:
1) Similar work parts in terms of raw material (e.g. metal shock for machining)
2) The work parts are produced in various sizes and geometries.
3) The work parts are produced in batches of small to medium size quantities.
4) A sequence of similar processing steps is required to complete the operation on each
workpiece.

CNC

Numerical CONTROL System with dedicated microcomputer is referred as computer numeric

control.It is located near the machine tool and the entire program is stored in its memory and
each part is controlled by memory rather from tape.
The programmer can easily write the codes and edit the programs as per the requirements.These
programs can be used for different parts, and they don’t have to be repeated again and again.
The CNC machine comprises of the computer in which the program is fed for cutting of the
metal of the job as per the requirements. All the cutting processes that are to be carried out and
all the final dimensions are fed into the computer via the program. The computer thus knows
what exactly is to be done and carries out all the cutting processes. NC machine works like the
Robot, which has to be fed with the program and it follows all your instructions.

Features of CNC.

1. Storage of more than one part programming

2. Program editing can be done at machine tool site.

3. Interpolation (linear and circular).

4. Fined cycle and programming subroutes.

5. Tool compensations using dedicated switches.

6. Speed and feed override.

7. Error imaging.

8. Scaling.

9. Suppression of implementation of a NC block.

10.On line part programming though difficult & time consuming.

DNC
It involves the use of large control computer to direct the operation of a number of separate
CNC machines and all machines are controlled by central computer through real time and direct
connection. On some CNC machine controllers, the available memory is too small to contain
the machining program (for example machining complex surfaces), so in this case the program
is stored in a separate computer and sent directly to the machine, one block at a time. If the
computer is connected to a number of machines it can distribute programs to different machines
as required. Usually, the manufacturer of the control provides suitable DNC software. However,
if this provision is not possible, some software companies provide DNC applications that fulfill
the purpose. DNC networking or DNC communication is always required when CAM programs
are to run on some CNC machine control.
Wireless DNC is also used in place of hard-wired versions. Controls of this type are very
widely used in industries with significant sheet metal fabrication, such as the automotive,
appliance, and aerospace industries.
Q1(B.)Explain position and feed control loop with suitable diagram.

POSITION CONTROL LOOP

The control cannot turn the handle wheels but can only give instructions to the control the
movememt of wheels.So all the slides are provided with feed motors.The control provides
signal to move the tool or workpiece.The signals are amplified by amplifier and passed onto the
feed motor in axes connected to move axis slide as per speed and duration of slide motions
already programmed or known to control.

є PROCESS CONTROLLER PROCESS

FEEDBACK MEASUREMENT

FEED CONTROL LOOP

FEED CONTROL LOOP

To control feed rate, each motor is equipped with tachometer which signals actual motor to
stepped to amplifier which control the difference between actual and programmed feed rate
and accelerate or deaccelerate the feed motor accordingly.

CIM stands for COMPUTER INTEGRATED MANUFACTURING. It stands for holistic

and methodological approach applied to all activities of enterprise in order to achieve
improvement in performance. It encompasses entire range of product development and
manufacturing functions with all functions being carried out by dedicated software packages. It
uses common database to integrate design, manufacturing and associated business activities.
It desires to meet following requirement:

1. Reduction in inventory.

2. Reduced waste.

3. Lower Product Waste.

4. Improvement of quality

5. Flexibilty in manufacturing

EVOLUTION OF CIM

CIM is considered a natural evolution of CAD/CAM.

The first major innovation in machine control is the numerical control(NC) demonstrated at
MIT in 1952.By late 1960’s mini computers were being commonly used to control NC
machines. This development is called CNC.Since 1970 numerical contyroller were being
designed around microprocessor ,resulting in compact CNC system. A further development in
this technology is DNC (distributed numeric control).Evolution of CAD on the other hand was
to cater the geometric modeling needs to automobile and aeronautical engineers. During 1980’s
,manufacturing was characterized by few stands of automation. Though it has realized that full
potentials of computers could not be obtained unless all the segment of manufacturing are
integrated .This realization led to the development of CIM. Thus implementation of CIM
required a whole lot of technologies (computer based) related to hardware & software.
PRODUCT DEVELOPMENT CYCLE IN CIM

It has the following stages.

1. Concept stage: First of all the concept of the desired product is developed and evolved

on the basis of customer requirement and market analysis.

2. Design stage: Then the design department establishes the initial database of proposed
product, done through geometric modeling and CAD and concepts generated by creativity of
design engineer.
3. Planning stage: The databse prepared by design engineer is further enriched with production
data and information to produce a detailed plan.
4. Manufacturing stage: It includes all the activities required to carry out (manufacturing of )
product.
5. Marketing stage: After production, efficient marketing is necessary to ensure adequate sales
and proper price realization. It involves identifying needs of the product and suggesting
improvements in existing product model.
6.Service stage: After sales service forms an essential component of the product development
cycle .It is essential to ensure consumer satisfaction in acse of shortcoming in the product and
allows scope for further improvements in the product.

What are the enabling technologies of CIM ?

The enabling technologies of CIM are as follows

1. COMPUTER AIDED DESIGN (CAD)

2. COMPUTER AIDED MANUFACTURE(CAM)
3. COMPUTER AIDED TEST(CAT)
4. MANUFACTURING PROCESS AND CONTROL
5. PROCES TECHNOLOGIES
6. ROBOTICS
7. AUTOMATED MATERIAL HANDLING
AUTOMATED CAD CAM
MATERIAL
HANDLING

CIM CAT

ROBOTICS PROCESS MANUFACTURING

POSITIONING PLANNING AND
DESIGN

ENABLING TECHNIQUE OF CIM

 EXPERIMENT NO-2

AIM:- What is FMS .Explain elements ,features and layout of FMS.Describe the role of FMS in
sheet metal industry with explanation of any one CNC machine tool.

THEORY:
FMS is highly complex and sophisticated DNC grouping of machines that combine efficiency
of transmission lines with the flexibility of job shop.
ELEMENTS OF FMS.

1. CNC Machine tools

2. Work-handling systems.
3. Pallets.
4. Buffer storage,Warehouses.
5. Sensing devices.
6. Handling systems.

FEATURES :

1.Means of reprogramming machines automatically.

2. Means of having all the tools necessary to machine workpiecve.

3.Means of transporting the workpiece between machines automatically loading and unloading
of machines.

The main advantages of an FMS is its high flexibility in managing manufacturing resources like
time and effort in order to manufacture a new product. The best application of FMS is found in
the production of small sets of products like those from a mass production. An industrial
flexible manufacturing system(FMS) consists of robots, computer controlled machines,
numerical controlled machines(CNC0,instrumentation devices,computers,sensors and other
stand alone systems such as inspection machines.The use of robots in the production segment of
manufacturing industries promises a variety of benefits ranging from high utilization to high
volume of productivity.Each robotic cell or node will be located along a material handling
system such as a conveyor or require a different combination of manufacturing nodes.The
movement of parts from one node to another is donethrough the material handling system.At
the end of the part processing,the finished parts will be routed to an automatic inspection node,
and subsequently unloaded from the flexible manufacturing system.

FMS LAYOUT

INSPECT
MC MC PALLET IO AS/RB
N UNIT

MANIPULATO
R

CONVEYOR/AGV
PATH

MANIPULATO
R

CLEANIN LOAD-
G UNLOAD
MC MC TOOL ROOM
UNIT SECTION
ROLE OF FMS IN SHEET METAL INDUSTRY

Sheet metal work/parts have been made by a range of traditional tools but with the advent of
CNC /NC technology it is possible to produce CNC press brake ,CNC turret punch press and
high speed sheet metal machining centres.
In a typical CNC punch press,60-72 tools to punch holes of different sizes and shapes are
available .The table can be used to carry upto 1.3*2.5 cm sheet. The tools are incorporated in
rotary heads.

PRINCIPAL FMS EQUIPMENT:

1.Automatic warehouse and automatic storage .

2.Unmanned carriage.

3.Material feed station and single sheet pack up unit.

4.Machine holder

5.Unloader.

6.Stacking system.

7.Sorter.

8.Turnover unit.

9.Tilting table.

Advantages

 Reduced manufacturing cost

 Lower cost per unit produced,
 Greater labor productivity,
 Greater machine efficiency,
 Improved quality,
 Increased system reliability,
  Reduced parts inventories,
 Adaptability to CAD/CAM operations.
 Shorter lead times
 Improved efficiency
 Increase production rate

Disadvantages

 Initial set-up cost is high,

 Substantial pre-planning
 Requirement of skilled labour
 Complicated system

An Industrial Flexible Manufacturing System (FMS) consists of robots, Computer-controlled

Machines, Numerical controlled machines (CNC), instrumentation devices, computers, sensors, and
other stand alone systems such as inspection machines. The use of robots in the production segment
of manufacturing industries promises a variety of benefits ranging from high utilization to high volume
of productivity. Each Robotic cell or node will be located along a material handling system such as a
conveyor or automatic guided vehicle. The production of each part or work-piece will require a
different combination of manufacturing nodes. The movement of parts from one node to another is
done through the material handling system. At the end of part processing, the finished parts will be
routed to an automatic inspection node, and subsequently unloaded from the Flexible Manufacturing
System.
 EXPERIMENT NO 3:
AIM:
TO STUDY CAPP, ITS TYPES AND FUTURE TRENDS IN CAPP
THEORY:
DEFINITION OF PROCESS PLANNING :
Process planning is concerned with determining the sequence of individual manufacturing operations needed to
produce a given part or product. The resulting operation sequence is documented on a form typically referred to
as a route sheet (also called as process sheet/method sheet) containing a listing of the production operations and
associated machine tools for a work part or assembly. Process planning in manufacturing also refers to the
planning of use of blanks, spare parts, packaging material, user instructions (manuals) etc.
The term "Computer-Aided Production Planning" is used in different contexts on different parts of the
production process; to some extent CAPP overlaps with the term "PIC" (Production and Inventory Control).
Process planning translates design information into the process steps and instructions to efficiently and
effectively manufacture products. As the design process is supported by many computer-aided tools,
computer-aided process planning (CAPP) has evolved to simplify and improve process planning and achieve
more effective use of manufacturing resources.
Process planning encompasses the activities and functions to prepare a detailed set of plans and instructions to
produce a part. The planning begins with engineering drawings, specifications, parts or material lists and a
forecast of demand. The results of the planning are:

 Routings which specify operations, operation sequences, work centers, standards, tooling and fixtures. This
routing becomes a major input to the manufacturing resource planning system to define operations for
production activity control purposes and define required resources for capacity requirements planning
purposes.
 Process plans which typically provide more detailed, step-by-step work instructions including dimensions
related to individual operations, machining parameters, set-up instructions, and quality assurance
checkpoints.
 Fabrication and assembly drawings to support manufacture (as opposed to engineering drawings to define
the part).
Computer-aided process planning initially evolved as a means to electronically store a process plan once it was
created, retrieve it, modify it for a new part and print the plan. Other capabilities were table-driven cost and
standard estimating systems, for sales representatives to create customer quotations and estimate delivery time.

TYPES OF COMPUTER AIDED PROCESS PLANNING :

There are two types of computer aided process Planning:-
1. Variant type CAPP- The variant approach involves retrieving an existing plan for a similar part
and making the necessary modifications to the plan for the new part.
2. Generative type CAPP- The generative approach involves generation of new process plans by
means of decision logics and process knowledge.

DESCRIPTION :

COMPUTER-AIDED PROCESS PLANNING

Manufacturers have been pursuing an evolutionary path to improve and computerize process planning in the
following five stages:
Stage I – Manual classification; standardized process plans
Stage II – Computer maintained process plans
Stage III – Variant CAPP
Stage IV – Generative CAPP
Stage V – Dynamic, generative CAPP
Prior to CAPP, manufacturers attempted to overcome the problems of manual process planning by basic
classification of parts into families and developing somewhat standardized process plans for parts families
(Stage I). When a new part was introduced, the process plan for that family would be manually retrieved,
marked-up and retyped. While this improved productivity, it did not improve the quality of the planning of
processes and it did not easily take into account the differences between parts in a family nor improvements in
production processes.
Computer-aided process planning initially evolved as a means to electronically store a process plan once it was
created, retrieve it, modify it for a new part and print the plan (Stage II). Other capabilities of this stage are
table-driven cost and standard estimating systems.
This initial computer-aided approach evolved into what is now known as “variant” CAPP. However, variant
CAPP is based on a Group Technology (GT) coding and classification approach to identify a larger number of
part attributes or parameters. These attributes allow the system to select a baseline process plan for the part
family and accomplish about ninety percent of the planning work. The planner will add the remaining ten
percent of the effort modifying or fine-tuning the process plan. The baseline process plans stored in the
computer are manually entered using a super planner concept,that is, developing standardized plans based on
the accumulated experience and knowledge of multiple planners and manufacturing engineers (Stage III).
The next stage of evolution is toward generative CAPP (Stage IV). At this stage, process planning decision
rules are built into the system. These decision rules will operate based on a part’s group technology or features
technology coding to produce a process plan that will require minimal manual interaction and modification
(e.g., entry of dimensions).
While CAPP systems are moving more and more towards being generative, a pure generative system that can
produce a complete process plan from part classification and other design data is a goal of the future. This type
of purely generative system (in Stage V) will involve the use of artificial intelligence type capabilities to
produce process plans as well as be fully integrated in a CIM environment. A further step in this stage is
dynamic, generative CAPP which would consider plant and machine capacities, tooling availability, work
center and equipment loads, and equipment status (e.g., maintenance downtime) in developing process plans.
The process plan developed with a CAPP system at Stage V would vary over time depending on the resources
and workload in the factory. For example, if a primary work center for an operation(s) was overloaded, the
generative planning process would evaluate work to be released involving that work center,alternate processes
and the related routings. The decision rules would result in process plans that would reduce the overloading on
the primary work center by using an alternate routing that would have the least cost impact. Since finite
scheduling systems are still in their infancy, this additional dimension to production scheduling is still a long
way off.
Dynamic, generative CAPP also implies the need for online display of the process plan on a workorder oriented
basis to insure that the appropriate process plan was provided to the floor. Tight integration with a
manufacturing resource planning system is needed to track shop floor status and load data and assess alternate
routings vis-a-vis the schedule.Finally, this stage of CAPP would directly feed shop floor equipment controllers
or, in a less automated environment,display assembly drawings online in conjunction with process plans.

CAPP PLANNING PROCESS

The system logic involved in establishing a variant process planning system is relatively straight forward – it is
one of matching a code with a pre-established process plan maintained in the system. The initial challenge is in
developing the GT classification and coding structure for the part families and in manually developing a
standard baseline process plan for each part family.
The first key to implementing a generative system is the development of decision rules appropriate for the items
to be processed. These decision rules are specified using decision trees, computer languages involving logical
“if-then” type statements, or artificial intelligence approaches with object-oriented programming.
The nature of the parts will affect the complexity of the decision rules for generative planning and ultimately the
degree of success in implementing the generative CAPP system.The majority of generative CAPP systems
implemented to date have focused on process planning for fabrication of sheet metal parts and less complex
machined parts. In addition, there has been significant recent effort with generative process planning for
assembly operations, including PCB assembly.
A second key to generative process planning is the available data related to the part to drive the planning.
Simple forms of generative planning systems may be driven by GT codes. Group technology or features
technology (FT) type classification without a numeric code may be used to drive CAPP. This approach would
involve a user responding to a series of questions about a part that in essence capture the same information as in
a GT or FT code. Eventually when features-oriented data is captured in a CAD system during the design
process, this data can directly drive CAPP.

GROUP TECHNOLOGY :
• Group Technology or GT is a manufacturing philosophy in which the parts having similarities (Geometry,
manufacturing process and/or function) are grouped together to achieve higher level of integration between the design and
manufacturing functions of a firm. The group of similar parts is known as part family and the group of machineries used
to process an individual part family is known as machine cell.
• It is not necessary for each part of a part family to be processed by every machine of corresponding machine cell. This
type of manufacturing in which a part family is produced by a machine cell is known as cellular manufacturing. The
manufacturing efficiencies are generally increased by employing GT because the required operations may be confined to
only a small cell and thus avoiding the need for transportation of in-process parts.
• Intuitive grouping is the simplest and most common method of creating part families. Experienced engineers and shop
people examine the product mix and separate products and parts into processing families. These part families become the
basis for work cells.
• When there are more than about 100 parts and more than a dozen or so processes, Production Flow Analysis (PFA) or
Coding & Classification is indicated.
GT and Manufacturing
Group Technology benefits manufacturing in many ways. It reduces the number and variety of parts. Process planning for
the remaining parts is easier and more consistent. Computer Aided Process Planning (CAPP) is an important tool for this.
It uses the coded similarities to plan consistently, standardize and accurately estimate costs. It then assigns the part to a
GT manufacturing cell. Group Technology cells reduce throughput time and Work-In-Process. They simplify schedules,
reduce transportation and ease supervision.
Advantages of Group Technology (GT) :
Major advantages of Group technology are in following areas:

 Product design- GT promotes standardization in product design

 Material handling- Grouping similar parts together in families results in efficient flow of material
on the shop floor and thus reduces material handling
 Tooling and set-ups- GT results in standardization of tools and set-ups such as jigs and fixtures and
doesn’t require any major changes, so set-up time is saved.
 Production and inventory control- Due to reduction in set up and more efficient material
handling lead time is reduced.

Summing up all the advantages of group technology

i. Increases the productivity
ii. Reduces overall cost
iii. Reduces lead time
iv. Promotes standardization of the process
v. Reduces set up time
vi. Reduces material handling
vii. Better inventory control
viii. Process planning is easier
ix. Process planning is faster
x. Improves the quality
xi. Simplifies process planning

ADVANTAGES OF COMPUTER AIDED PROCESS

PLANNING :
Variant CAPP
Advantages of Variant CAPP
Following advantages are associated with variant process planning approach:
(i) Processing and evaluation of complicated activities and managerial issues are done in an efficient
manner. Hence lead to the reduction of time and labour requirement.
(ii) Structuring manufacturing knowledge of the process plans to company’s needs through standardized
procedures.
(iii) Reduced development and hardware cost and shorter development time. This is an essential issue for
small and medium scale companies, where product variety is not so high and process planner are
interested in establishing their own process planning research activities.

Generative CAPP
Advantages of Generative Process Planning
Generative process plans have a number of advantages. Among the major ones are the following :
(i) They rely less on group technology code numbers since the process, usually uses decision tree to
categorize parts into families.
 (ii) Maintenance and updating of stored process plans are largely unnecessary. Since, any plan may be
quickly regenerated by processing through the tree.
(iii) Indeed, many argue that with generable systems, process plans should not be stored since if the
process is changed, and out-of-dated process plan might find its way back into the system.
(iv) The process logic rules however must be maintained up to dated and ready for use. This provides the
process planner with an assurance that the processes generated will reflect state-of-the-art
technology.

LIMITATIONS OF COMPUTER AIDED PROCESS PLANNING

:
Variant CAPP
Limitations of variant CAPP
Following disadvantages are associated with variant process planning approach :
(i) It is difficult to maintain consistency during editing.
(ii) Proper accommodation of various combinations of attributes such as material, geometry, size,
precision, quality, alternate processing sequence and machine loading among many other factors are
difficult.
(iii) The quality of the final process plan largely depends on the knowledge and experience of process
planner. The dependency on process planner is one of the major shortcomings of variant process
planning.

Generative CAPP
Limitations of generative CAPP
Some of the limitations of Generative CAPP can be stated as follow :
(i) The development of the system in the beginning is a difficult The development of the system in the
beginning is a difficult
(ii) It requires major revisions if a new equipment or processing capabilities became available.
capabilities became available.
(iii) Forward or backward planning can be done. Forward or backward planning can be done. Forward
planning suffers from conditioning problems; the Forward planning suffers from conditioning
problems; the results of a setup affects the next set up. results of a setup affects the next set up.
Computer Aided Process Planning
Overall advantages and limitations of Computer Aided Process
Planning(CAPP)
Advantages of CAPP :
Automated process planning brings about following advantages :

1. Decrease in the needed skill of the process planner.

2. Decrease in process planning time.
3. Decrease in costs because of efficient use of resources.
4. Production of accurate and consistent process plans.
5. Enhanced productivity and process rationalisation.
6. Maximisation of just-in-time performance

Disadvantages of CAPP :
CAPP systems have few disadvantages which can be listed as :

(i) The inability to show special manufacturing techniques.

(ii) The initial cost of establishing a CAPP system is high while compared with manual process planning.

FUTURE OF CAPP :
Generative or dynamic CAPP is the main focus of development, the ability to automatically generate
production plans for new products, or dynamically update production plans on the basis of resource
availability. Generative CAPP will probably use iterative methods, where simple production plans are applied
to automatic CAD/CAM development to refine the initial production plan.

Generative CAPP systems are built on a factory’s production capabilities and capacities. In Discrete
Manufacturing, Art-to-Part validations have been performed often, but when considering highly volatile
engineering designs, and multiple manufacturing operations with multiple tooling options, the decisions tables
become longer and the vector matrices more complex. Unlike a Variant Process Planning system that modifies
existing plans, each process plan could be defined automatically, independent of past routings. As
improvements are made to production efficiencies, the improvements are automatically incorporated into the
current production mix. This generative system is a key component of the CAPP system for the Agile
Manufacturing environment.

Traditional CAPP methods that optimize plans in a linear manner have not been able to satisfy the need for
flexible planning, so new dynamic systems will explore all possible combinations of production processes, and
then generate plans according to available machining resources. For example, K.S. Lee et al. states that "By
considering the multi-selection tasks simultaneously, a specially designed genetic algorithm searches through
the entire solution space to identify the optimal plan".
 EXPERIMENT NO-4

AIM: To Study computer aided programming. APT for CNC Machine tools and various elements of APT.
THEORY:
Computer-Assisted Part Programming
• In computer-assisted part programming (APT), the machining instructions are written in English-like statem ents that
are subsequently translated by the computer into the low-level machine code that can be interpreted and executed by
the machine tool controller.
• When using one of the part programming languages, the two main tasks of the programmer are: (1) Defining the
geometry of the workpart.
(2) Specifying the tool path and operation sequence.
•To program in APT, the part geometry must first be defined. Then the tool is directed to various point locations and
along surfaces of the workpart to accomplish the required machining operations.
• The viewpoint of the programmer is that the workpiece remains stationary, and the tool is instructed to move relative
to the part.
• To complete the program, speeds and feeds must be specified, tools must be called, tolerances must be given for
circular interpolation, and so forth.
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.
• The statements are constructed of APT vocabulary words, symbols, and numbers, all arranged using appropriate
punctuation.
• APT vocabulary words consist of six or fewer characters.
• Most APT statements include a slash (/) as part of the punctuation.
• APT vocabulary words that immediately precede the slash are called major words, whereas those that follow the
slash are called minor words.

Geometry Statements
SYMBOL = GEOMETRY TYPE/DESCRIPTIVE DATA
Points P1 = POINT/20.0,40.0,60.0
P2 = POINT/INTOF,L1,L2
• Commas are used to separate the words and numerical values in the descriptive data.
Geometry Statements
Lines
• A line defined in APT is considered to be infinite length in both directions. Also, APT treats a line as a vertical plane
that is perpendicular to the x-y plane.
L3 = LINE/P3,P4
L4 = LINE/P5,PARLEL,L3
Geometry Statements
Circles
• In APT, a circle is considered to be a cylindrical surface that is perpendicular to the x-y plane and extends to infinity
in the z-direction.
C1 = CIRCLE/CENTER,P1,RADIUS,25.0
C2 = CIRCLE/P4,P5,P6
Planes
• In APT, a plane extends indefinitely.
PL1 = PLANE/P1,P2,P3
PL2 = PLANE/P2,PARLEL,PL1
Geometry Statements
Rules for formulating APT geometry statements:
1. Coordinate data must be specified in the order x, then y, then z.
2. Any symbols used as descriptive data must have been previously defined.
3. A symbol can be used to define only one geometry element.
4. Only one symbol can be used to define any given element.
Example Part Geometry Using APT

Example Part Geometry Using APT

Example Part Geometry Using APT

P1 = POINT/0,0,0
P2 = POINT/160.0,0,0
P3 = POINT/160.0,60.0,0
P4 = POINT/35.0,90.0,0
P5 = POINT/70.0,30.0,0
P6 = POINT/120.0,30.0,0
P7 = POINT/70.0,60.0,0
P8 = POINT/130.0,60.0,0
L1 = LINE/P1,P2
L2 = LINE/P2,P3 C1 = CIRCLE/CENTER,P8,RADIUS,30.0
L3 = LINE/P4,PARLEL,L1
L4 = LINE/P4,P1
Motion Commands
The format of an APT motion command is:
MOTION COMMAND/DESCRIPTIVE DATA
Example: GOTO/P1
• 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
• At the beginning of the sequence of motion statements, the tool must be given a starting point. This is likely to be the
target point, the location where the operator has positioned the tool at the start of the job. 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; and PTARG is the symbol
assigned to the starting point. Another way to make this statement is the following:
• FROM/-20.0,-20.0,0
• The FROM statement occurs only at the start of the motion sequence.
Motion Commands
Point-to-point motions
There are only two commands: GOTO and GODLTA.
• The GOTO statement instructs the tool to go to a particular point location specified in the descriptive data.
Examples: GOTO/P2
GOTO/25.0,40.0,0
• In the first command, P2 is the destination of the tool point. In the second command, the tool has been instructed to
go to the location whose coordinates are x=25.0, y=40.0, and z=0.
• The GODLTA command specifies an incremental move for the tool. To illustrate, the following statement instructs
the tool to move from its present position by a distance of 50.0mm in the x-direction, 120.0mm in the y direction, and
40.0mm in the z-direction:
GODLTA/50.0,120.0,40.0
Motion Commands
Point-to-point motions
•The GODLTA statement is useful in drilling and related machining operations. The tool can be directed to go to a
given hole location; then the GODLTA command can be used to drill the hole, as in the following sequence:
GOTO/P2
GODLTA/0,0,-50.0
GODLTA/0,0,50.0
Motion Commands
Contouring Motion Commands
• The tool's position must be continuously controlled throughout the move. The tool is directed along two intersecting
surfaces until it reaches a third surface, as shown in the following Figure.
• These three surfaces have specific names in APT; they are:
1.Drive surface. This surface guides the side of the cutter.
2.Part surface. This is the surface 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.
One might say that this surface "checks" the advance of the tool.
Motion Commands

The surfaces in APT contouring motions that guide the cutting tool.
Motion Commands
There are several ways in which the check surface can be used. This is determined by using any of four APT modifier
words in the descriptive data of the motion statement. The four modifier words are TO, ON, PAST, and TANTO.
Use of APT modifier words in motion statements:
(a) TO moves the tool into initial contact with the check surface;
(b) ON positions the tool center on the check surface;
(c) PAST moves the tool just beyond the check surface.

• In writing a motion statement, the part programmer must keep in mind the direction from which the tool is coming in
the preceding motion.
• The programmer must pretend to be riding on the top of the tool, as if driving a car.
• After the tool reaches the check surface in the preceding move, does the next move involve a right turn or left turn or
what? The answer to this question is determined by one of the following six motion words, whose interpretations are
illustrated in the following figure:

Use of the APT motion words. The tool has moved from a previous position to its present position. The direction of
the next move is determined by one of the APT motion words GOLFT, GORGT, GOFWD, GOBACK, GOUP, or
GODOWN.
To begin the sequence of motion commands, the FROM statement is used. The statement following the FROM
command defines the initial drive surface, part surface, and check surface. With reference to the following figure, the
sequence takes the following form: FROM/PTARG GO/TO,PL1,TO,PL2,TO,PL3
• The symbol PTARG represents the target point where the operator has set up the tool. The GO command instructs
the tool to move to the intersection of the drive surface (PL1), the part surface (PL2), and the check surface (PL3).
Because the modifier word TO has been used for each of the three surfaces, the circumference of the cutter is tangent
to PL1 and PL3, and the bottom of the cutter is on PL2. The three surfaces included in the GO statement must be
specified in the order:
(1) drive surface, (2) part surface, and (3) check surface.

Postprocessor and Auxiliary Statements A complete APT part program must include functions not accomplished by
geometry statements and motion commands. These additional functions are implemented by postprocessor statements
and auxiliary 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 the following:
Postprocessor and Auxiliary Statements POSTPROCCER COMMAND/DESCRIPTIVE DATA
Where the POSTPROCESSOR COMMAND is an APT major word including the type of function or action to be
accomplished, and the descriptive data consists of APT minor words and numerical values. In some commands, the
descriptive data is omitted.
Examples:
• UNITS/MM indicates that the specified units in the program are INCHES or MM.
• INTOL/0.02 specifies inward tolerance for circular interpolation (OUTTOL/0.02).
• SPINDL/1000,CLW specifies spindle rotation speed in revolutions per minute. Either CLW (clockwise) or CCLW
(counterclockwise) can be specified. (SPINDL/OFF).
• CUTTER/20 defines cutter diameter for tool path offset calculation • DELAY/30 temporarily stops the machine tool
for a period specified in seconds.
• FEDRAT/40,IPM specifies feedrate in mm/min or in/min as specifies in UNITS statements. (FEDRAT/4,IPR)
• RAPID engage high feedrate for next moves.
• COOLNT/FLOOD turns fluid one (COOLNT/MIST) (COOLNT/OFF)
• LOADTL/01 used with automatic tool changing.
Postprocessor and 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.
Examples:
• PARTNO is the first statement in an APT program, used to identify the program; for example, PARTNO SAMPLE
PART NUMBER ONE
• REMARK is used to insert explanatory comments into the program that are not interpreted or processed by the APT
processor.
• FINI indicates the end of an APT program.
 EXPERIMENT NO-5

AIM : TO WRITE A PROGRAMME IN APT LANGUAGE TO PRODUCE A MILD STEEL

CYLINDRICAL COMPONENT ON CNC LATHE.

PROGRAMME:

ISN 1 : PART NO/12345

ISN 2 : MACHINE / CHURCH ,4 ,300 ,100 ,2200 ,573 , 3 , 44

ISN 3 : LOAD /573 ,1, 1 LOW , START

ISN 4 : SPINDLE / 500 ,LOW 93

ISN 5 : CUTTER / 1.6

ISN 6 : FEED RATE / 0.200

ISN 7 : RGT / 3-40

ISN 8 : L1 = L/4 AXIS – 50.5

ISN 9 : GO / TO , L1

ISN 10 : L2 = L/4 AXIS -70.5

ISN 11 : GL / L2 , PAST L2

ISN 12 : GD/0 -20

ISN 13 : RG1/3 -60

ISN 14 : L3 –L / X AXIS – 50.5

ISN 15 : FEDRAT / 0.200

ISN 16 : GO/TO L3

ISN 17 : L4 = L/4 X-AXIS -160

ISN 18 : GL / L3 , 0 LY

ISN 19 : GD/0 -30

ISN 20 : R,GT /3 -60

ISN 21 : LS= L/ X AXIS , -25.5

ISN 22 : FEDRAT / 0.200

ISN 23 : GO/TO 1L5

ISN 24 : L6 = L/YAXIS –GO

ISN 25 : GL/L5 , TO L6

ISN 26 : GD/0 -30

ISN 27 : R, GT / 3, -60

ISN 28 : LOAD TL /512 , 1 , 1 , LOAD START

ISN 29 : L7 = L/X AXIS -90

ISN 30 : FEDRAT / 0.200

ISN 31 : GO/TO L7

ISN 32 : GL/L7 PART L2

ISN 33 : GD/ 0 , -20

ISN 34 : R,GT /3 , -60

ISN 35 : L8 = L/X AXIS -50

ISN 36 : FEDRAT / 0.200

ISN 37 : GO/TO ,L8

ISN 38 : GL/L8 , TO ,L4

ISN 39 : GD/0 , -30

ISN 40 : R,GT /3 ,-60

ISN 41 : LG =L/X –AXIS , -25

ISN 42 : FEDRAT /0.200

ISN 43 : GO/TO L9

ISN 44 :GL/L9 , TO L6

ISN 45 : GD/0 , -30

ISN 46 : COOLANT /OFF

ISN 47 : FINI
 EXPERIMENT NO-6
AIM:
To study G codes and M codes with their applications.
THEORY:
For any operation of a CNC/m/c tool,there is a separate command,which is given in the form of a
program.This program contains codes which allows the different slides and tools to operate.A typical line of a
CNC programme(called block) is given by:
N0040 G01 * 100.05 4180.95 5450 M08
Every block starts with a block number(3 or4 digits) at least one NC function (C word) X,Y,Z
coordinates,feed(F) and a M word called miscellaneous function,Each word has a unique alphabetic address.
G-codes and G-functions are mainly NC functions.They are also called preparatory functions.Some of these
have been assigned standard functions and others are left to be defined by the CNC manufacturing:
1) Interpolation functions
2) Thread cutting
3) Feed functions
4) Reference point
5) Coordinate system setting
6) Inch-metric conversion
7) Canned cycles
8) Multi-repetetive cycle
9) Compensation functions
10) Measurement functions
M-functions are mainly switching functions.These includes spindle ON/OFF,spindle rotation coolant
ON/OFF,tool change,pallet change,turret indexing etc.
G CODES:

Milling Turning
Code Description Corollary info
(M) (T)

G00 On 2- or 3-axis moves, G00 (unlike G01)

traditionally does not necessarily move in
a single straight line between start point
and end point. It moves each axis at its
max speed until its vector quantity is
achieved. Shorter vector usually finishes
first (given similar axis speeds). This
Rapid positioning M T matters because it may yield a dog-leg or
hockey-stick motion, which the
programmer needs to consider depending
on what obstacles are nearby, to avoid a
crash. Some machines offer interpolated
rapids as a feature for ease of
programming (safe to assume a straight
line).

G01 The most common workhorse code for

feeding during a cut. The program specs
the start and end points, and the control
automatically calculates (interpolates) the
intermediate points to pass through that
will yield a straight line (hence "linear").
The control then calculates the angular
Linear interpolation M T velocities at which to turn the
axis leadscrews via their servomotors or
stepper motors. The computer performs
thousands of calculations per second, and
the motors react quickly to each input.
Thus the actual toolpath of the machining
takes place with the given feedrate on a
path that is accurately linear to within very
 small limits.

G02 Very similar in concept to G01. Again, the

control interpolates intermediate points
and commands the servo- or stepper
motors to rotate the amount needed for the
leadscrew to translate the motion to the
correct tool tip positioning. This process
repeated thousands of times per minute
generates the desired toolpath. In the case
of G02, the interpolation generates a circle
rather than a line. As with G01, the actual
toolpath of the machining takes place with
the given feedrate on a path that accurately
matches the ideal (in G02's case, a circle)
to within very small limits. In fact, the
interpolation is so precise (when all
Circular interpolation, conditions are correct) that milling an
M T
clockwise interpolated circle can obviate operations
such as drilling, and often even fine
boring. Addresses for radius or arc
center: G02 and G03 take either
an R address (for the radius desired on the
part) or IJK addresses (for the component
vectors that define the vector from the arc
start point to the arc center point). Cutter
comp: On most controls you cannot
start G41 or G42 in G02 or G03 modes.
You must already have compensated in an
earlier G01 block. Often a short linear
lead-in movement will be programmed,
merely to allow cutter compensation
before the main event, the circle-cutting,
begins. Full circles: When the arc start
 point and the arc end point are identical, a
360° arc, a full circle, will be cut. (Some
older controls cannot support this because
arcs cannot cross between quadrants of the
cartesian system. Instead, four quarter-
circle arcs are programmed back-to-back.)

G03 Circular interpolation,

M T Same corollary info as for G02.
counterclockwise

G04 Takes an address for dwell period (may

be X, U, or P). The dwell period is
specified by a control parameter, typically
set to milliseconds. Some machines can
accept either X1.0 (s) or P1000 (ms),
which are equivalent. Choosing dwell
duration: Often the dwell needs only to
last one or two full spindle rotations. This
Dwell M T is typically much less than one second. Be
aware when choosing a duration value that
a long dwell is a waste of cycle time. In
some situations it won't matter, but for
high-volume repetitive production (over
thousands of cycles), it is worth
calculating that perhaps you only need
100 ms, and you can call it 200 to be safe,
but 1000 is just a waste (too long).

G05 P10000 Uses a deep look-ahead buffer and

High-precision contour simulation processing to provide better
M
control (HPCC) axis movement acceleration and
deceleration during contour milling

G05.1 Q1. Uses a deep look-ahead buffer and

AI Advanced Preview simulation processing to provide better
M
Control axis movement acceleration and
deceleration during contour milling
G06.1 Activates Non-Uniform Rational B Spline
Non-uniform rational B-
for complex curve and waveform
spline (NURBS) M
machining (this code is confirmed in
Machining
Mazatrol 640M ISO Programming)

G07 Imaginary axis

M
designation

G09 Exact stop check, non-

M T The modal version is G61.
modal

G10 Modifies the value of work coordinate and

Programmable data input M T
tool offsets[6]

G11 Data write cancel M T

G12 Fixed cycle for ease of programming 360°

Full-circle interpolation, circular interpolation with blend-radius
M
clockwise lead-in and lead-out. Not standard on
Fanuc controls.

G13 Fixed cycle for ease of programming 360°

Full-circle interpolation, circular interpolation with blend-radius
M
counterclockwise lead-in and lead-out. Not standard on
Fanuc controls.

G17 XY plane selection M

G18 On most CNC lathes (built 1960s to

2000s), ZX is the only available plane, so
no G17 to G19 codes are used. This is now
changing as the era begins in which live
tooling, multitask/multifunction, and mill-
ZX plane selection M T
turn/turn-mill gradually become the "new
normal". But the simpler, traditional form
factor will probably not disappear—it will
just move over to make room for the
newer configurations. See also V address.

G19 YZ plane selection M

G20 Somewhat uncommon except in USA and
(to lesser extent) Canada and UK.
However, in the global marketplace,
competence with both G20 and G21
always stands some chance of being
necessary at any time. The usual minimum
Programming in inches M T increment in G20 is one ten-thousandth of
an inch (0.0001"), which is a larger
distance than the usual minimum
increment in G21 (one thousandth of a
millimeter, .001 mm, that is,
one micrometre). This physical difference
sometimes favors G21 programming.

G21 Prevalent worldwide. However, in the

Programming global marketplace, competence with both
M T
in millimeters (mm) G20 and G21 always stands some chance
of being necessary at any time.

G28 Takes X Y Z addresses which define the

Return to home position intermediate point that the tool tip will
(machine zero, aka M T pass through on its way home to machine
machine reference point) zero. They are in terms of part zero (aka
program zero), NOT machine zero.

G30 Takes a P address

specifying which machine zero point is
desired, if the machine has several
Return to secondary
secondary points (P1 to P4). Takes X Y Z
home position (machine
M T addresses which define the intermediate
zero, aka machine
point that the tool tip will pass through on
reference point)
its way home to machine zero. They are in
terms of part zero (aka program zero),
NOT machine zero.

G31 Skip function (used for

M
probes and tool length
 measurement systems)

G32 Single-point threading, Similar to G01 linear interpolation, except

longhand style (if not T with automatic spindle synchronization
using a cycle, e.g., G76) for single-point threading.

G33 Constant-pitch threading M

G33 Single-point threading,

Some lathe controls assign this mode to
longhand style (if not T
G33 rather than G32.
using a cycle, e.g., G76)

G34 Variable-pitch threading M

G40 Tool radius Turn off cutter radius compensation

M T
compensation off (CRC). Cancels G41 or G42.

G41 Turn on cutter radius compensation

(CRC), left, for climb milling.
Milling: Given righthand-helix cutter
and M03 spindle direction, G41
corresponds to climb milling (down
milling). Takes an address (D or H) that
calls an offset register value for radius.
Turning: Often needs no D or H address
on lathes, because whatever tool is active
automatically calls its geometry offsets
Tool radius
M T with it. (Each turret station is bound to its
compensation left
geometry offset register.)
G41 and G42 for milling has been partially
automated and obviated (although not
completely) since CAM programming has
become more common. CAM systems
allow the user to program as if with a zero-
diameter cutter. The fundamental concept
of cutter radius compensation is still in
play (i.e., that the surface produced will be
distance R away from the cutter center),
 but the programming mindset is different;
the human does not choreograph the
toolpath with conscious, painstaking
attention to G41, G42, and G40, because
the CAM software takes care of it. The
software has various CRC mode
selections, such as computer, control,
wear, reverse wear, off, some of which do
not use G41/G42 at all (good for roughing,
or wide finish tolerances), and others
which use it so that the wear offset can
still be tweaked at the machine (better for
tight finish tolerances).

G42 Turn on cutter radius compensation

(CRC), right, for conventional milling.
Tool radius Similar corollary info as for G41. Given
M T
compensation right righthand-helix cutter and M03 spindle
direction, G42 corresponds
to conventional milling (up milling).

G43 Takes an address, usually H, to call the

tool length offset register value. The value
Tool height offset
M is negative because it will be added to the
compensation negative
gauge line position. G43 is the commonly
used version (vs G44).

G44 Takes an address, usually H, to call the

tool length offset register value. The value
Tool height offset
M is positive because it will
compensation positive
be subtracted from the gauge line position.
G44 is the seldom-used version (vs G43).

G45 Axis offset single

M
increase

G46 Axis offset single M

 decrease

G47 Axis offset double

M
increase

G48 Axis offset double

M
decrease

G49 Tool length offset

M Cancels G43 or G44.
compensation cancel

G50 Takes an S address integer which is

interpreted as rpm. Without this
Define the maximum
T feature, G96 mode (CSS) would rev the
spindle speed
spindle to "wide open throttle" when
closely approaching the axis of rotation.

G50 Scaling function cancel M

G50 Position register is one of the original

methods to relate the part (program)
coordinate system to the tool position,
which indirectly relates it to the machine
coordinate system, the only position the
control really "knows". Not commonly
programmed anymore because G54 to
G59 (WCSs) are a better, newer method.
Position register Called via G50 for turning, G92 for
(programming of vector T milling. Those G addresses also have
from part zero to tool tip) alternate meanings (which see). Position
register can still be useful for datum shift
programming. The "manual absolute"
switch, which has very few useful
applications in WCS contexts, was more
useful in position register contexts,
because it allowed the operator to move
the tool to a certain distance from the part
(for example, by touching off a 2.0000"
 gage) and then declare to the control what
the distance-to-go shall be (2.0000).

G52 Temporarily shifts program zero to a new

location. It is simply "an offset from an
offset", that is, an additional offset added
onto the WCS offset. This simplifies
programming in some cases. The typical
example is moving from part to part in a
multipart setup. With G54 active, G52
X140.0 Y170.0 shifts program zero
140 mm over in X and 170 mm over in Y.
When the part "over there" is done, G52
Local coordinate system
M X0 Y0 returns program zero to normal
(LCS)
G54 (by reducing G52 offset to nothing).
The same result can also be achieved (1)
using multiple WCS origins,
G54/G55/G56/G57/G58/G59; (2) on
newer controls, G54.1 P1/P2/P3/etc. (all
the way up to P48); or (3) using G10 for
programmable data input, in which the
program can write new offset values to the
offset registers. Which method to use
depends on shop-specific application.

G53 Takes absolute coordinates (X,Y,Z,A,B,C)

with reference to machine zero rather than
program zero. Can be helpful for tool
Machine coordinate
M T changes. Nonmodal and absolute only.
system
Subsequent blocks are interpreted as "back
to G54" even if it is not explicitly
programmed.

G54 to G59 Have largely replaced position register

Work coordinate systems
M T (G50 and G92). Each tuple of axis offsets
(WCSs)
relates program zero directly to machine
 zero. Standard is 6 tuples (G54 to G59),
with optional extensibility to 48 more via
G54.1 P1 to P48.

G54.1 P1 to Up to 48 more WCSs besides the 6

P48 provided as standard by G54 to G59. Note
floating-point extension of G-code data
Extended work
M T type (formerly all integers). Other
coordinate systems
examples have also evolved (e.g., G84.2).
Modern controls have the hardware to
handle it.

G61 Can be canceled with G64. The non-modal

Exact stop check, modal M T
version is G09.

G62 Automatic corner

M T
override

G64 Default cutting mode

(cancel exact stop check M T Cancels G61.
mode)

G68 Rotates coordinate system in the current

plane given with G17 G18 or G19. Center
of rotation is given with two parameters,
which vary with each vendors
implementation. Rotate with angle given
Rotate coordinate
M with argument R. This can be for instance
system.
be used to align coordinate system with
misaligned part. It can also be used to
repeat movement sequences around a
center. Not all vendors support coordinate
system rotation.

G69 Turn off coordinate

M Cancels G68.
system rotation.

G70 Fixed cycle, multiple

T
repetitive cycle, for
 finishing (including
contours)

G71 Fixed cycle, multiple

repetitive cycle, for
T
roughing (Z-axis
emphasis)

G72 Fixed cycle, multiple

repetitive cycle, for
T
roughing (X-axis
emphasis)

G73 Fixed cycle, multiple

repetitive cycle, for
T
roughing, with pattern
repetition

G73 Peck drilling cycle for Retracts only as far as a clearance

milling – high-speed increment (system parameter). For when
M
(NO full retraction from chipbreaking is the main concern, but chip
pecks) clogging of flutes is not. Compare G83.

G74 Peck drilling cycle for

T
turning

G74 Tapping cycle for

milling, lefthand
M See notes at G84.
thread, M04 spindle
direction

G75 Peck grooving cycle for

T
turning

G76 Includes OSS and shift (oriented spindle

Fine boring cycle for
M stop and shift tool off centerline for
milling
retraction)

G76 Threading cycle for

T
turning, multiple
 repetitive cycle

G80 Milling: Cancels all cycles such

as G73, G81, G83, etc. Z-axis returns
either to Z-initial level or R level, as
programmed (G98 or G99, respectively).
Cancel canned cycle M T
Turning: Usually not needed on lathes,
because a new group-1 G address
(G00 to G03) cancels whatever cycle was
active.

G81 Simple drilling cycle M No dwell built in

G82 Dwells at hole bottom (Z-depth) for the

number of milliseconds specified by
the P address. Good for when hole bottom
Drilling cycle with dwell M finish matters. Good for spot drilling
because the divot will be certain to clean
up evenly. Consider the "choosing dwell
duration" note at G04.

G83 Peck drilling cycle (full Returns to R-level after each peck. Good
M
retraction from pecks) for clearing flutes of chips. Compare G73.

G84 G74 and G84 are the righthand and

Tapping cycle, righthand lefthand "pair" for old-school tapping with
thread, M03 spindle M a non-rigid toolholder ("tapping head"
direction style). Compare the rigid tapping
"pair", G84.2 and G84.3.

G84.2 See notes at G84. Rigid tapping

synchronizes speed and feed according to
Tapping cycle, righthand the desired thread helix. That is, it
thread, M03 spindle synchronizes degrees of spindle rotation
M
direction, rigid with microns of axial travel. Therefore, it
toolholder can use a rigid toolholder to hold the tap.
This feature is not available on old
machines or newer low-end machines,
 which must use "tapping head" motion
(G74/G84).

G84.3 Tapping cycle, lefthand

thread, M04 spindle
M See notes at G84 and G84.2.
direction, rigid
toolholder

G85  Good cycle for a reamer.

 In some cases good for single-point
boring tool, although in other cases
the lack of depth of cut on the way
boring cycle, feed in/feed
M back out is bad for surface finish,
out
in which case, G76 (OSS/shift) can
be used instead.
 If need dwell at hole bottom,
see G89.

G86 Boring tool will leave a slight score mark

on the way back out. Appropriate cycle for
boring cycle, feed
M some applications; for
in/spindle stop/rapid out
others, G76 (OSS/shift) can be used
instead.

G87 For backboring. Returns to initial level

only (G98); this cycle cannot
boring cycle, backboring M use G99 because its R level is on the far
side of the part, away from the spindle
headstock.

G88 boring cycle, feed

in/spindle stop/manual M
operation

G89 boring cycle, feed G89 is like G85 but with dwell added at
M
in/dwell/feed out bottom of hole.

G90 Positioning defined with reference to part

Absolute programming M T (B)
zero.
 Milling: Always as above.
Turning: Sometimes as above (Fanuc
group type B and similarly designed), but
on most lathes (Fanuc group type A and
similarly designed), G90/G91 are not used
for absolute/incremental modes.
Instead, U and W are the incremental
addresses and X and Z are the absolute
addresses. On these lathes, G90 is instead
a fixed cycle address for roughing.

G90 Fixed cycle, simple

When not serving for absolute
cycle, for roughing (Z- T (A)
programming (above)
axis emphasis)

G91 Positioning defined with reference to

previous position.
Milling: Always as above.
Turning: Sometimes as above (Fanuc
group type B and similarly designed), but
Incremental on most lathes (Fanuc group type A and
M T (B)
programming similarly designed), G90/G91 are not used
for absolute/incremental modes.
Instead, U and W are the incremental
addresses and X and Z are the absolute
addresses. On these lathes, G90 is a fixed
cycle address for roughing.

G92 Same corollary info as at G50 position

register.
Milling: Always as above.
Position register
Turning: Sometimes as above (Fanuc
(programming of vector M T (B)
group type B and similarly designed), but
from part zero to tool tip)
on most lathes (Fanuc group type A and
similarly designed), position register
is G50.
G92 Threading cycle, simple
T (A)
cycle

G94 On group type A lathes, feedrate per

Feedrate per minute M T (B)
minute is G98.

G94 Fixed cycle, simple

When not serving for feedrate per minute
cycle, for roughing (X- T (A)
(above)
axis emphasis)

G95 On group type A lathes, feedrate per

Feedrate per revolution M T (B)
revolution is G99.

G96 Varies spindle speed automatically to

achieve a constant surface speed.
Constant surface speed See speeds and feeds. Takes an S address
T
(CSS) integer, which is interpreted
as sfm in G20 mode or as m/min
in G21 mode.

G97 Takes an S address integer, which is

interpreted as rev/min (rpm). The default
Constant spindle speed M T
speed mode per system parameter if no
mode is programmed.

G98 Return to initial Z level

M
in canned cycle

G98 Feedrate per minute Feedrate per minute is G94 on group type
T (A)
(group type A) B.

G99 Return to R level in

M
canned cycle

G99 Feedrate per revolution Feedrate per revolution is G95 on group

T (A)
(group type A) type B.

MISCELLANEOUS FUNCTION(M-CODES)

Code Description Milling Turning Corollary info

 (M) (T)

M00 Non-optional—machine will always stop upon

Compulsory stop M T
reaching M00 in the program execution.

M01 Machine will only stop at M01 if operator has

Optional stop M T
pushed the optional stop button.

M02 Program ends; execution may or may not return to

program top (depending on the control); may or may
not reset register values. M02 was the original
program-end code, now considered obsolete, but
End of program M T
still supported for backward compatibility.[7] Many
modern controls treat M02 as equivalent
to M30.[7] See M30 for additional discussion of
control status upon executing M02 or M30.

M03 The speed of the spindle is determined by the

address S, in either revolutions per
minute (G97 mode; default) or surface feet per
minute or [surface] meters per minute (G96 mode
[CSS] under either G20 or G21). The right-hand
rule can be used to determine which direction is
Spindle on clockwise and which direction is counter-clockwise.
M T
(clockwise rotation) Right-hand-helix screws moving in the tightening
direction (and right-hand-helix flutes spinning in the
cutting direction) are defined as moving in the M03
direction, and are labeled "clockwise" by
convention. The M03 direction is always M03
regardless of local vantage point and local
CW/CCW distinction.

M04 Spindle on
(counterclockwise M T See comment above at M03.
rotation)

M05 Spindle stop M T

M06 Automatic tool M T (some- Many lathes do not use M06 because the T address
 change (ATC) times) itself indexes the turret.
Programming on any particular machine tool
requires knowing which method that machine uses.
To understand how the T address works and how it
interacts (or not) with M06, one must study the
various methods, such as lathe turret programming,
ATC fixed tool selection, ATC random memory tool
selection, the concept of "next tool waiting", and
empty tools. These concepts are taught in textbooks
such as Smid,[3] and online multimedia (videos,
simulators, etc.); all of these teaching resources are
usually paywalled to pay back the costs of their
development. They are used in training classes for
operators, both on-site and remotely (e.g., Tooling
University).

M07 Coolant on (mist) M T

M08 Coolant on (flood) M T

M09 Coolant off M T

M10 Pallet clamp on M For machining centers with pallet changers

M11 Pallet clamp off M For machining centers with pallet changers

M13 This one M-code does the work of

Spindle on
both M03 and M08. It is not unusual for specific
(clockwise rotation)
M machine models to have such combined commands,
and coolant on
which make for shorter, more quickly written
(flood)
programs.

M19 Spindle orientation is more often called within

cycles (automatically) or during setup (manually),
but it is also available under program control
Spindle orientation M T via M19. The abbreviation OSS (oriented spindle
stop) may be seen in reference to an oriented stop
within cycles.
The relevance of spindle orientation has increased
 as technology has advanced. Although 4- and 5-axis
contour milling and CNC single-pointing have
depended on spindle position encoders for decades,
before the advent of widespread live tooling and
mill-turn/turn-mill systems, it was seldom relevant
in "regular" (non-"special") machining for the
operator (as opposed to the machine) to know the
angular orientation of a spindle except for within a
few restricted contexts (such as tool change,
or G76 fine boring cycles with choreographed tool
retraction). Most milling of features indexed around
a turned workpiece was accomplished with separate
operations on indexing head setups; in a sense,
indexing heads were invented as separate pieces of
equipment, to be used in separate operations, which
could provide precise spindle orientation in a world
where it otherwise mostly didn't exist (and didn't
need to). But as CAD/CAM and multiaxis CNC
machining with multiple rotary-cutter axes becomes
the norm, even for "regular" (non-"special")
applications, machinists now frequently care about
stepping just about any spindle through its 360° with
precision.

M21 Mirror, X-axis M

M21 Tailstock forward T

M22 Mirror, Y-axis M

M22 Tailstock backward T

M23 Mirror OFF M

Thread gradual
M23 T
pullout ON

M24 Thread gradual

T
pullout OFF
M30 Today M30 is considered the standard program-end
code, and will return execution to the top of the
program. Today most controls also still support the
original program-end code, M02, usually by treating
it as equivalent to M30. Additional
info: Compare M02 with M30. First, M02 was
created, in the days when the punched tape was
End of program,
expected to be short enough to be spliced into a
with return to M T
continuous loop (which is why on old controls, M02
program top
triggered no tape rewinding).[7] The other program-
end code, M30, was added later to accommodate
longer punched tapes, which were wound on
a reel and thus needed rewinding before another
cycle could start.[7]On many newer controls, there is
no longer a difference in how the codes are
executed—both act like M30.

M41 Gear select – gear 1 T

M42 Gear select – gear 2 T

M43 Gear select – gear 3 T

M44 Gear select – gear 4 T

M48 Feedrate override

M T
allowed

M49 Prevent MFO. This rule is also usually called

(automatically) within tapping cycles or single-point
Feedrate override threading cycles, where feed is precisely correlated
M T
NOT allowed to speed. Same with spindle speed override (SSO)
and feed hold button. Some controls are capable of
providing SSO and MFO during threading.

M52 Unload Last tool

M T Also empty spindle.
from spindle

M60 Automatic pallet

M For machining centers with pallet changers
change (APC)
M98 Takes an address P to specify which subprogram to
Subprogram call M T call, for example, "M98 P8979" calls subprogram
O8979.

M99 Usually placed at end of subprogram, where it

returns execution control to the main program. The
default is that control returns to the block following
the M98 call in the main program. Return to a
Subprogram end M T
different block number can be specified by a P
address. M99 can also be used in main program with
block skip for endless loop of main program on bar
work on lathes (until operator toggles block skip).

The mark ‘W’ or ‘A’ means with or after ‘W’ type M command start their operation with the axis motion
commands in the same programme block and A’type’ does it after finishing of the axis motion.
 EXPERIMENT NO-7

AIM :

To study the construction and working of SCORBOT ER4U robot and its safety features.

THEORY: The SCORBOT – ER 4u ROBOT is a versatile and reliable system for educational use . the robot arm can be
mounted on a tabletop , pedestal or linear slide base . The robot’s speed and repeatability make it highly suited for both
stand-alone operations and integrated use in automated

Workcell applications such as robotic welding , machine vidion, CNC machine tending and other FMS operations. The
robot is supported by robo cell 3d graphic software that lets student design , create and control simulated industrial
workcell , robocells is fully integrated with scorbase robotics programming and control software and provides dynamic
simulation of the robot and workcell devices during visual program execution . the scorbot – er 4u is a powerful tool for
teaching science and technology in the classroom or lab . many teachers have already discovered its potential subject
such as:

MATHEMATICS: use the robot to demonstrate 3- dimensional space and coordinate systems

PHYSICS: combine the robot with motion sensor and tracking software to measure and test physical properties such as
speed, velocity and acceleration . take advantage of the robot’s open structure to observe and study the principles of
power transmission.

COMPUTER SCIENCE: program complex conditional statements to solve logic problems such as the Hanoi tower and
have the robot execute the manipulation task.

TECHNOLOGY: use the robot controller’s digital and analog input/output capabilities to create monitor systems
controlled by the physical properties such as light , temperature or sound.

SPECIFICATIONS:

MECHANICAL ARM

 MECHANICAL STRUCTURE : Vertically articulated ; open frame

 degrees of freedom : 5 rotational axes and gripper
 payload of capacity : 2.1 kg
 reach : 610 mm (24”) with gripper
 speed : 700 mm/sec (27.6”/sec)
 repeatability : + - 0.18 mm (0.07”)
 position feedback : incremental optional encoders
 homing : micro switch on each axis
 gripper : DC servo motor , 2-finger parallel
 gripper jaw opening : 0-65/75 mm ( 2.6 “/3”)

 transmission : gears, timing belts , lead

AXIS RANGE
  Axis 1 : BASE ROTATION 310
 AXIS 2 : SHOULDER ROTATION +130/-35
 AXIS 3 : ELBOW ROTATION +130
 AXIS 5 : WRIST ROLL +- 570
CONTROLLER

 communication : USB type A cable connection to PC; plug and play without rebboting
 inputs/outputs : 8 digital inputs ; 4 analog inputs; 8 digital outputs (4 relay , 4 open collector ); analog outputs

 microcontroller : full featured , nev v853 risc 32 – bit microcontroller.

 axis servo control : real- time ; pid ; pwm
 servo axes : 8 (robot arm , gripper and 2 peripheral devices)
 user memory : unlimited programs , program lines and variables, positions.
 position definition : absolute , relative , Cartesian, joints, encoders
 trajectory control : joint,linear, circular
 speed definations : 100 speed settings (percentages); travel time definition; millimetre per second (mm/sec) For
robot linear movement.
 control parameters : 160 user – accessible parameters
 safety features : emergency switch ; short – circuit
 Protection ; automatic shut – down upon detection of impact, overheating , pc failure or communication error.
SOFTWARE

 SCORBASE : ROBOTIC PROGRAMMING & OPERATION SOFTWARE

 ROBOCELL : 3D GRAPHIC SIMUlation software (optional) enables offline design and simulation of
virtual robotic cell and online graphic tracking of actual cell.
ACCESSORIES (OPTIONAL) : teach pendant , linear belt conveyor , rotary index table , linear slidebases ,
sensors xy positioning table , parts feeders , i/o experiment table, pneumatic grippers , end effectors ,
MACHINE VISION SYSTEM , WORKBENCHES , COORDINATING GRID.
 EXPERIMENT NO-8

AIM: Define Industrial Robot, Discuss its configuration and sensors used in robots.

THEORY:
An industrial robot is a genral purpose programmable machine possessing certain
anthropomorphic characteristics, the most typical being its arm .This arm together with the
robot capacity to be programmed makes it suited for various industrial tasks like welding.

CONFIGURATIONS

Polar Coordinate Configuration

It is called spherical coordinates because the walks pace with which it can move its arm is a
partial sphere.
Cylindrical Coordinate Configuration

The robot is a vertical column that survives about the vertical axes.The arm consists of several
orthogonal slides which allows arm to be moved up or down in and out w.r.t body
Joined Arm Configuration

Similar appearance as human arm,it consists of several straight members connected by joints
which are analogous to human shoulder,elbow to wrist.
Cartesian Coordinate Configuration

A robot connected around this configuration ahs 3 orthogonal slides parallel to x,y,z axes of

Cartesian coordinate system.By appropriate movement of these slides ,the robot is capable
moving its arm to any point within its 3d rectangularity shaped workspace.
There are 6 basic motions on degrees of freedom.

ARMS AND BODY MOTION

1.VERTICAL TRANSVERSE

2.RADIAL TRANSVERSE

3.RELATIONAL TRANSVERSE
WRIST MOTION

1.WRIST

2.WRIST BEND

3.WRIST JAW

ROBOTIC SENSORS

1.VISON SENSORS: It is made possible by means of video camera ,light source and a
computer program to process image data.Computer software enables the vision system to sense
the pressure of an object and its possible orientation.
2.TACTILE PROXIMITY SENSORS:It provides the robot the capability to respond to
contact force between itself and other programs.
Torch sensor- used to indicate whether the contact has been made with an object.A microswitch
can serve the purpose.
Stress sensor-Used to measure magnitude of force .Strain gauges are used to sense them

3.VOICE SENSORS: Some robot has a set of stored word pattern and performs a specific task
when a match is formed between input and stored vocabulary word.This speeds up the
programming process.

INDUSTRIAL APPLICATIONS OF ROBOTS

1.PART HANDLING: Robots are used in recognizing
,sorting,reporting,loading,unloading,palletizing,etc.
2.PART PROCESSING: Robots can also perform the functions such as
welding,routing,drilling ,coating ,grinding,etc.
3.PRODUCT BUILDING:Robots can also be used in assembly works like assembling of
.electric motors, car bodies ,circuit boards, solenoid, etc.
 EXPERIMENT NO-9

AIM:
To study and program spectralight CNC millimg machine for a given component

THEORY:
CNC milling is a specific form of computer numeric controlled machining. Milling itself is a machining process
similar to both drilling and cutting like drilling, milling uses a rotating cylindrical cutting tool. Milling is the
machining process of using rotary cutters to remove material[1] from a workpiece by advancing (or feeding) in
a direction at an angle with the axis of the tool.It covers a wide variety of different operations and machines,
on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most
commonly used processes in industry and machine shops today for machining parts to precise sizes and
shapes.

Milling can be done with a wide range of machine tools. The original class of machine tools for milling was the
milling machine (often called a mill). After the advent of computer numerical control (CNC), milling machines
evolved into machining centers (milling machines with automatic tool changers, tool magazines or carousels,
CNC control, coolant systems, and enclosures), generally classified as vertical machining centers (VMCs) and
horizontal machining centers (HMCs). The integration of milling into turning environments and of turning into
milling environments, begun with live tooling for lathes and the occasional use of mills for turning operations,
led to a new class of machine tools, multitasking machines (MTMs), which are purpose-built to provide for a
default machining strategy of using any combination of milling and turning within the same work envelope.

PROCESS:
Milling is a cutting process that uses a milling cutter to remove material from the surface of a workpiece. The
milling cutter is a rotary cutting tool, often with multiple cutting points. As opposed to drilling, where the tool
is advanced along its rotation axis, the cutter in milling is usually moved perpendicular to its axis so that
cutting occurs on the circumference of the cutter. As the milling cutter enters the workpiece, the cutting edges
(flutes or teeth) of the tool repeatedly cut into and exit from the material, shaving off chips (swarf) from the
workpiece with each pass. The cutting action is shear deformation; material is pushed off the workpiece in tiny
clumps that hang together to a greater or lesser extent (depending on the material) to form chips. This makes
metal cutting somewhat different (in its mechanics) from slicing softer materials with a blade.

The milling process removes material by performing many separate, small cuts. This is accomplished by using a
cutter with many teeth, spinning the cutter at high speed, or advancing the material through the cutter slowly;
most often it is some combination of these three approaches.[2] The speeds and feeds used are varied to suit
a combination of variables. The speed at which the piece advances through the cutter is called feed rate, or
just feed; it is most often measured in length of material per full revolution of the cutter.

TYPES OF CNC MILLING MACHINES:

 1) The vertical CNC milling machine and the vertical machining centre(VMC) are the most common CNC
machine tools found in job shops today.
2) They are very agile machines and can be easily adapted to a variety of workpiece.Vertical CNC milling
machines are easy to load.
3) The horizontal machining centre is similar in construction to the conventional horizontal milling
machine.
4) Most CNC milling machines also have an automatic tool changes(ATC).It enables the machine to run
unattempted all the way through the cycle.
PROGRAMMING FOR CNC MILLING MACHINE OPERATIONS:
In case of CNC milling machine,motion is possible along allthesev axis.the z axis is the axis of the spindle and
any movement of the tool/workpiece which takes the cutting tool away from the workpiece. A canned cycle is
a way of conveniently performing repetitive CNC machine operations. Canned cycles automate certain
machining functions such as drilling, boring, threading, pocketing, etc...[1] Canned cycles are so called because
they allow a concise way to program a machine to produce a feature of a part.[2] A canned cycle is also known
as a fixed cycle. A canned cycle is usually permanently stored as a pre-program in the machine's controller and
cannot be altered by the user.

ADVANTAGES OF CNC MILLING:

1) Greater throughput-5 times faster on average
2) Greater precision-Typically 0.0001 inch or better
3) Automated cooling
4) APT facilitates integration with CAD programs
5) Design with CAD
6) Build with CNC
LIMITATIONS OF CNC MILLING:
1)The general limitations of CNC Milling are prototype size, axis movement, and drill bit size.

2)The size and shape limitations will vary by the machine used. The largest machines are capable of machining
pieces up to 105 feet by 21 feet (These are gantry mills, needed by such companies as Boeing mill large pieces
of aluminum). The smallest machines have travels of 9 inches in the x-axis, 5.125 inches in the y-axis, and 6.5
inches in the z-axis.

3)The shape limitations include the inability to bore square-edged holes in the material.
COSTS ASSOCIATED WITH CNC MILLING:
1) The initial cost of the equipment is quite high.

2) These are costs for programming the machine as used as for the use of computer time.

3) The material and the design complexities dictates the cost most dramatically.

4) Some other factors include preventive and ongoing maintenance of the CNC milling equipment.