Source: P.N.

Rao, CAD/CAM
  Know about
 Machine tools
 Cutting Tools
 Fixtures
 Manufacturing processes
 Knowledge of geometry, algebra and
trigonometry.
 Machine shop experience as well

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1. Process planning
2. Axes selection
3. Tool selection
4. Cutting process parameters planning
5. Job and tool setup planning
6. Machining path planning
7. Part program writing
8. Part program proving

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 Study part print

Identify machine Machine

tool tool
databace

Identify operations
Capability
of cutting
and tooling
Cutting
tools tool
database
Determine feeds,
speeds, depths,
power
Machinability
database

Prepare setup
sheet with work
setting and tooling
assembly

Develop part
program

Simulate tool
path

Dry run

Cut the first part

Inspect the part Proven part

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Detailed plan of the steps involved in
manufacturing/machining a given part
 Machine tool used
 Fixtures required
 Sequence of operations
 For each operations
 Cutting tools required
 Process parameters
 Study part drawing
 Based on accuracy, availability etc
 Total cost

10 November 2017 5
 15 15
20

10
Process Plan:
Ø
6 1. Endmill the top face 100x100mm
2. Endmill the steps, 20x100x5mm
R5
3. Mill pocket, 40x40x8mm
40
10

40
4. Drill the six holes, Φ6x15mm
10

20

100
15
5

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• ISO designation of axis- choose accordingly.
• Reference poistion/ fixed datum/home position
• Floating datum- free to choose any datum
• Choose to minimize calculations
• Keep all in first quadrant
• Z-axis datum is top of the work piece, generally
• Symmetric cases- center of work piece

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 Y
35

50
6 20
Ø

10
30
20
R5 X
40

50

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 Y
100
70

6
Ø

R5
100

40
80

60
50
40
20

X
15
30
85
Z 15

X
5
8

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 • Right tool for the job and economy
• Regular tools- no special tooling required
• For a contour- end mill or slot drill?
• Size of the tool
• Choose largest size for surface finish and MRR

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• Parameters:
• refer to hand book
• Feeds, speeds- as high as possible
• Set-up
• Setting the job and adjusting the cutting tool
• Path
• Path connected to cost
• Canned cycles

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Writing:
Write program according to format and syntax

Proving:
• Check that program is correct
• Simulate
• Trial run without Tool/work piece
• Trial with cheaper material as well

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1. Computer drawing
2. Process-planning sheet
3. Tool cards
4. Set-up sheet
5. Programming sheets
6. Punched paper tape (if that is the case)

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10 November 2017 16
• Word address format
• An alphabet followed by numeric data (E.g.: N105)
• Quickly processed by controller
• Blocks start with Nxxx (N100)

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 A Angular dimension around X axis
 B Angular dimension around Y axis
 C Angular dimension around Z axis
 F Feed function
 G Preparatory function
 H Unassigned
 I Distance to arc centre or thread lead parallel to X
 J Distance to arc centre or thread lead parallel to Y
 K Distance to arc centre or thread lead parallel to Z
 M Miscellaneous function
 N Sequence number
 O Reference rewind stop
 S Spindle speed function
 T Tool function
 U Secondary motion dimension parallel to X*
 V Secondary motion dimension parallel to Y*
 W Secondary motion dimension parallel to Z*
 X Primary X motion dimension
 Y Primary Y motion dimension
 Z Primary Z motion dimension
 D,E,P,Q,R,U,V and W are not used

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 ISO standards for coding
 Co-ordinate function
 Feed function (F mm per minute)
 Speed function (S rpm)
 Tool function (T15)
 Comment using ‘()’
 N010 G00 Z50.0 M05 (spindle stops and rapidly moves)
 G Codes
 M Codes

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 G- preset function associated with the movement of
machine axes and the associated geometry
 Two digits: G01, G42, G90….
 Some controllers- 3 digits
 ISO standards
 Most manufacturers follow
 Some remain until overridden by another G
 Some are common in all controllers
 Fanuc, MAHO,

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 G00 Point-to-point positioning, rapid traverse
 G01 Line interpolation
 G02 Circular interpolation, clockwise (WC)
 G03 Circular interpolation, anti-clockwise (CCW)
 G04 Dwell
 G13-G16 Axis designation
 G17 XY plane designation
 G18 ZX plane designation
 G19 YZ plane designation
 G33 Thread cutting, constant lead
 G34 Thread cutting, linearly increasing lead
 G35 Thread cutting, linearly decreasing lead
 G40 Cutter compensation-cancels to zero
 G41 Cutter radius compensation-offset left
 G42 Cutter radius compensation-offset right
 G43 Cutter compensation-positive
 G44 Cutter compensation-negative

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 G53 Deletion of zero offset
 G54-G59 Datum point/zero shift
 G63 Tapping cycle
 G64 Change in feed rate or speed
 G70 Dimensioning in inch units
 G71 Dimensioning in metric units - default
 G80 Canned cycle cancelled
 G81-G89 Canned drilling and boring cycles
 G90 Specifies absolute input dimensions
 G91 Specifies incremental input dimensions
 G92 Programmed reference point shift
 G94 Feed rate/min (inch units when combined with G70)
 G95 Feed rate/rev (metric units when combined with G71)
 G96 Spindle feed rate for constant surface feed
 G97 Spindle speed in revolutions per minute

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Y N007 G90 G01 X5.0 Y10.0
N008 X25.0 Y15.0
N009 X35.0 Y5.0

N007 G91 G01 X5.0 Y10.0

N008 X20.0 Y5.0
B N009 X10.0 Y-10.0
15 A
10
C
5
O
X
5 25 35
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 • Unit Group- G70, G71
• Active Plane- G17, G18, G19
• Preset- G92
• N015 G92 X200.0 Y 170.0 Z25.0
• Motion group: G00, G01, G02, G03
• G00- move tool rapidly

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 Z

G17

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 Y

X Z

G17

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 Z

G18

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 Z

Y
G19

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10 November 2017 29
 Y
A Go to B from A:
N105 G90 G00 X150.0 Y30.0

45° C B

A 30
X
20
150

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 Y
N115 G01 X110.0 Y30.0 F250
D

100
E

30
X
20
110

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 N125 G02 X65.0 Y60.0 I35.0 J-10.0 F250
Y N130 G03 X15.0 Y30.0 I-15.0 J-40.0 F250

G
F
20

30
X
R3

15
5

50
65

10 November 2017 32
• Functions operate some controls on the machine tools and
affect running of m/c
• One code in a block- usually
• ISO codes

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 M00 Program stop, spindle and coolant off
 M01 Optional programmable stop
 M02 End of program-often interchangeable with M30
 M03 Spindle on, CW
 M04 Spindle on, CCW
 M05 Spindle stop
 M06 Tool change
 M07 Coolant supply No. 1 on
 M08 Coolant supply No. 2 on
 M09 Coolant off
 M13 Spindle on, CW + coolant on
 M14 Spindle on, CCW + coolant on
 M19 Spindle stop at specified angular position
 M30 Program stop at end tape + tape rewind

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 Y
125
The component to be machined is
shown in Fig. 13.20. It is assumed
that the pocket is through and hence R R3
5
C 10 D
only outside is to be machined as a
finish cut of the pocket. The tool to 100
be used is a 20 mm diameter slot 75 1 0
drill. If an end mill is to be used the 50 B R E
program should be modified with a 25
hole to be drilled at B first before the A X
25
end mill is used. The setting is done 65
Z
with point A as reference (0, 0, 0)
and the reference axes are along X X
10
and Y directions.

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 Y
125

5
R
C 10 D R3

100
75 1 0
50 B R E
25
A X
25
65
Z

X
10

N001 G92 X0 Y0 Z0 (absolute presetting at A)

(absolute programming)
N002 G90
N003 G00 X25.0 Y25.0 Z2.0 T01 S3000 M03
(tool brought rapidly at B, mm above XY plane)
N004 G01 Z-12.0 F120 (tool goes down to full depth)
N005 Y75.0 (proceeds to C)
N006 X65.0 (proceeds towards right to D)
N007 G02 Y25.0 I0 J-25.0 (cuts curved profile till E)
N008 G01 X25.0 (proceeds to B)
N009 Z2.0 (tool moves 2 mm above the XY plane)
N010 G00 Z50.0 M05 (spindle stops and rapidly moves up)
N011 X0 Y0 (rapid move to start position 0,0)
N012 M30 (end of program and tape rewind)

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10 November 2017 37
10 November 2017 38
 Y 98
20

98
80

18.757 20
X

Z 18.757
80
2 X
5

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 Y

Cutter centre path
R

R
 
Y  R tan  
2



Y1

Part contour
Y2

X
X1
X2

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 %
 O1002 (Program number)
 N010 G71 G92 X0 Y0 Z50 (Set point)
 N015 G90 (Absolute programming)
 N020 T01 S500 M06 (Tool change speed setting)
 N025 G00 Z2.0 M03 (Rapid move to clearance plane)
 N030 G01 Z-5.0 F100 (Feed to the required depth)
 N035 Y80.0 F120 (Cut along straight line)
 N040 G02 X20.0 Y98.0 R20.0 F100 (Circular move)
 N045 G01 X98.0 (Cut along straight line)
 N050 Y20 (Cut along straight line)
 N055 G02 X80.0 Y2.0 R18.0 (Circular move)
 N060 G01 X18.757 (Straight line to the intersection point)
 N065 X2.0 Y18.757 (Straight line to the intersection point)
 N070 Z2.0 M05 (Feed to clearance plane Stop spindle)
 N075 G0 X0 Y0 Z50 (Rapid to set point)
 N080 M02 (End of program)

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10 November 2017 42
 Z TOOL
1 2 3 4

L2

L4
L3

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 Canned cycle or fixed cycles are the G-codes used to
combine a number of common motions that are used
with some types of operations such as drilling of
holes.

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 N G81 X Y Z R

RAP
ID

Clearance plane

FEED

RAPID
Depth
Hole

Breakthrough
distance

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 Y
N010 G81 X25.0 Y35.0 Z-18.0 R2.0 F125 *
100 N015 X55.0 Y50.0 *
N020 X75.0 Y70.0 *
D N025 G80 X0 Y0 Z50 *
C
B 100
Ø1
0
70
50
35

A X
25
55
Z 75
15

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Canned Feed from At programmed depth Used for
cycle surface (end of feed point)
number Dwell Spindle Spindle
speed return
motion
G80 Off -- Stop -- Cancel canned cycle
G81 Constant -- -- Rapid Drilling, centre drilling
G82 Constant Yes -- Rapid Counter sinking, Counter boring
G83 Intermittent -- -- Rapid Deep hole drilling
G84 Constant -- Reverse Feed Tapping
G85 Constant -- -- Feed Reaming
G86 Constant -- Stop Rapid Boring
G87 Constant -- Stop Manual Multiple Boring
G88 Constant Yes Stop Manual Boring
G89 Constant Yes -- Feed Boring

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 2 xØ10 mm dia holes 50 10

The component to be
machined is shown in
Fig. 13.29. Write a
100
program using canned Ø20

cycles to drill all the 50

holes shown in Fig

13.29. 100
All dimensions in mm

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%
O1303
N010 G71 G92 X0 Y0 Z50
N015 G90
N020 T01 S800 M06
N025 G82 X25 Y25 Z-5 R2 P2 F125 M03 (Centre drill all holes)
N030 X25 Y75
N035 X75 Y25
N040 G80 X-50 Y0 Z50 M05
N045 T02
N050 G81
S800 M06
X25 Y25 Z-13 R2 F125 M03
(Finish Drill the 20 hole)
N055 G80 X-50 Y0 Z50 M05
N060 T03
N065 G81
S800 M06
X25 Y75 Z-13 R2 F125 M03
(Finish Drill the 10 holes)
N070 X75 Y25
N075 G80 X-50 Y-50 Z50 M05
N080 T00 M05
N090 M02

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10 November 2017 50
 130
Y 115
95
80

100
84 84
60
34 40
16
X
20
40
Cutting tools:
60
1 End mill Ø40 mm
8 2 Centre drill
20 10 3 Twist drill Ø6 mm
4 Twist drill Ø8.5 mm
5 Tap M10

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10 November 2017 52
 G40, G41, G42
10 30 12 70 90
0

10

20
Programmed Path

40
Offset Path of Cutter

60

80

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 Y Set point
1 G42 A
2

110 G40
6

90
140

60 X
3
4

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 100
A

41
60
F
G
B C
K

L
Ø2 42
0
200

0
12
Ø
E D
J
H
200

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 70.432 R10

84.574

20
46.642
120 91.645
77.503
R15
R10 R15
39.571
25.607 33
15 22.5
10

4.393 53.713
124.853
134.799

10

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10 November 2017 57
A complete part program using Drill Ø7 mm thru
Counterbore Ø10 x 7 mm deep Drill Ø5 mm thru
Bore Ø5.5 mm thru
the ISO codes for the following (2) places
+0.00
Ream Ø6 +0.005 thru
A
component for the different
holes present in the component
shown in Fig. 13.40. The cutting
speed to be used is 50 m/min 37.5

and the feed rate is 0.08 mm/rev. Y

12.5
Use the lower left hand corner of X
12.5 A 18.75
the part as the datum. 62.5

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 Given V = 50 m/min and f = 0.08 mm/rev
1000 V 1000  50
Spindle speed, N =   2273.64 rpm
 D  7
Feed to be used = 0.080 × 2200 = 176 mm/min

Op. Description Tool required Spindle, Feed,

No. RPM mm/min
10 Drill two holes Twist drill 7 mm dia 2200 175
20 Counter bore two holes End mill 10 mm dia 1590 125
30 Drill two holes Twist drill 5 mm dia 3180 250
40 Bore the two holes Boring bar 5.5 mm dia 2890 230
50 Ream two holes Reamer 6 mm dia 2650 210

10 November 2017 59
%
O1308 (P N Rao)
N010 G71 G92 X0 Y0 Z50 (September 22, 2008)
N015 G90 (Stock 75 x 50 x 20mm)
N020 T01 S2200 M06 (Drill 7 mm diameter)
N025 G81 X12.5 Y37.5 Z-22.0 R2.0 F175 M03 (Start drilling)
N030 X62.5 Y12.5
N035 G80 X-50.0 Z50.0 (End of cycle)
N040 T02 S1590 M06 (End mill 10 mm diameter)
N045 G82 X12.5 Y37.5 Z-7.0 P1.0 R2.0 F125
N050 X62.5 Y12.5
N055 G80 X-50.0 Z50.0 (End of cycle)
N060 T03 S3180 M06 (Drill 5 mm diameter)
N065 G81 X12.5 Y12.5 Z-22.0 R2.0 F250
N070 X62.5 Y37.5
N075 G80 X-50.0 Z50.0 (End of cycle)
N080 T04 S2890 M06 (Bore 5.5 mm diameter)
N085 G86 X12.5 Y12.5 Z-22.0 R2.0 F230 (Boring cycle)
N090 X62.5 Y37.5
N095 G80 X-50.0 Z50.0 (End of cycle)
N100 T05 S2650 M06 (Reamer 6 mm diameter)
N105 G85 X12.5 Y12.5 Z-22.0 R2.0 F210 (Reaming cycle)
N110 X62.5 Y37.5
N115 G80 X-50.0 Z50.0 M05 (End of cycle)
N120 G00 X-50.0 Y-50.0
N130 M02 (End of program)

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10 November 2017 61
  Part programming is a systematic activity and following
the steps in proper sequence will help in developing
efficient part programs
 Selection of the part coordinate axes system with
respect to the part geometry help in reducing the
mathematical calculations that are needed to write the part
program
 ISO standard for part programming utilises all the 26
characters of English alphabet as word addresses in a part
program.
 Preparatory functions or G-codes control the geometrical
nature of the data input as well as operation of some of the
data in a program. A large number of these codes are
standardised by ISO.
10 November 2017 62
  Motion commands are the most important part of the G-codes used
to control the motion in rapid (G00), linear interpolation (G01) and
Circular interpolation (G02 and G03).
 Miscellaneous functions or M-codes are used to specify the machine
tool functions in the program. Less number of codes are standardised
in view of these being machine specific.
 For programs involving multiple tools, tool length compensation can
be activated by the use of tool offset registers.
 Canned or fixed cycles offer the facility to reduce the bulk of
program by canning the often repeated command into a single G-code.
Examples are for the drilling of holes (G81).
 In milling of contours large amount of complex calculations are often
required to take multiple cuts. This can be reduced by the use of cutter
diameter compensation (G41 and G42).

10 November 2017 63