TA202A - Manufacturing Processes II

NC Programming

Lecture 4

Mohit Law
Mechanical Engineering
[email protected]

Machine Tool IIT Kanpur

Dynamics Laboratory
How will you program the machine to do this?

https://www.youtube.com/watch?v=IbV4vIYUg1U

Machine Tool 2 IIT Kanpur

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CNC codes and the CNC executive

• NC programs are written in an internationally recognized standard language, called NC

codes.
• The CNC executive is the main system software that decodes the NC codes block by
block and sends appropriate commands to physical control, computation, and PLC units
of the CNC system.
• For example, a 10-mm distance to be traveled at a 200-mm/s feed velocity command
can be translated as follows: The real-time clock is set to generate 10,000 pulses at a
rate of 200,000 pulses/s (1 pulse = 0.001 mm position). The position pulses (i.e., the
discrete velocity commands) are directed to the indicated machine tool axis position
control units by converting to their analog voltage equivalent (i.e., typically within ±10 V
range). The analog voltage is amplified by the power unit and fed to the axis drive
motors to deliver the desired motion.
• Miscellaneous functions, such as spindle ON and tool change commands, are translated
as Boolean logic signals (+5 V or −5 V) for PLC units.
Source: Altintas’s Mfg. Automation book

Machine Tool 3 IIT Kanpur

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NC part program structure

N040 G91 X25.00 Y10.00 Z−12.55 F150.0 S1100 T06 M03 M07

Block Incremental Move to these With this feed Use Turn spindle &
number approach coordinates and speed tool # 6 coolant ‘ON’

Load tool number 6 on the spindle (T06), rotate the spindle CW at 1,100 rev/min
(S1100, M03) and turn the cutting fluid on (M07) before the motion starts. Move the
machine tool in 25 mm, 10 mm, and 12.55 mm increments (G91) in the x, y, and z
directions with the resultant feeding velocity of 150 mm/min along the tool path.
N040 represents the 40th block sequence of the entire part program
Source: Altintas’s Mfg. Automation book

Machine Tool 4 IIT Kanpur

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Some commonly used NC words
N : Block sequence number.
G : Preparatory function.
X : Primary X motion dimension.
Y : Primary Y motion dimension.
Z : Primary Z motion dimension.
U, V, W : Secondary motion parallel to X, Y, Z axis respectively.
A, B, C : Angular dimension about X, Y, Z axis respectively.
F : Feed word.
M : Miscellaneous function.
S : Spindle speed word.
T : Tool number word.
R : Rapid traverse dimension in Z axis. Source: Altintas’s Mfg. Automation book

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Important preparatory (G) functions

• G00: Rapid point-to-point positioning

• G01: Linear interpolation. The tool path velocity is kept constant
at the given feed along the indicated straight line.
• G02, G03: Circular interpolation CW (G02) or CCW (G03).
• G33: Constant lead thread cutting.
• G70: Mode for programming in imperial (inch) units.
• G71: Mode for programming in metric (mm) units.
• G90: Coordinate inputs are given in absolute coordinates from a fixed Cartesian
coordinate center.
• G91: Coordinate inputs are given incrementally from a previous tool location.
• G92: Showing where the part zero is.
Source: Altintas’s Mfg. Automation book

Machine Tool 6 IIT Kanpur

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Linear interpolation

The velocities of two axes are controlled to keep the tool on a straight path in a plane
of motion. To keep the end mill following the straight line (𝑃1 𝑃2 ) at a given vector
feed velocity, the linear interpolation command G01 must be used.
y

𝑃1 10,12 ;
𝑃2 60,37 ;

x
Absolute programming mode Incremental programming mode

N0010 G90 G01 X60.0 Y37.0 F300.0 or N0010 G91 G01 X50.0 Y25.0 F300.0
Source: Altintas’s Mfg. Automation book

Machine Tool 7 IIT Kanpur

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Circular interpolation in milling

The velocities of two axes on a plane of motion are varied to keep the tool following
the given arc at the specified feed velocity. Some CNC systems require the coordinates
of the arc center and arc’s end point, whereas others need the radius of the arc and its
end point. CNC assumes that the tool is located at the beginning point of the arc.

Using the radius and the end point of the arc

N010 G90 G03 X x2 Y y2 Rrc F f.

or
Using center point of the arc and the arc’s end point

N010 G90 G03 X x2 Y y2 I ic J jc F f,

wherein: ic = xc − x1, jc = yc − y1.

Source: Altintas’s Mfg. Automation book

Machine Tool 8 IIT Kanpur

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Important miscellaneous (M) functions

• M00: Program stop. Terminates further program execution after the completion of
other commands in the block.
• M01: Optional stop if it is enabled by the operator. The program continues after the
execution of a continue command by the operator.
• M02: End of program indicating completion of machining cycle. Stops spindle,
coolant, and feed after the completion of all commands in the last NC block.
• M03, M04: Start spindle CW (M03) or CCW (M04).
• M05: Spindle off.
• M06: Tool change.
• M07, M08: Cutting fluid ON (M07), OFF (M08).
• M30: End of program. It stops feed, spindle, and cutting fluid and rewinds the NC
program to the beginning.
• M49: Prevents operator from overriding spindle and feed speeds. Source: Altintas’s Mfg. Automation book

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Write a CNC program (G code) to make this part

P0 (0,0,0)
Source: Altintas’s Mfg. Automation book

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First, preparatory functions

N01 G90 - Absolute coordinates

N02 G71 - Metric units (mm)

Source: Altintas’s Mfg. Automation book

Machine Tool 11 IIT Kanpur

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Then, place the cutter with respect to the part

N03 G92 X-12.5 Y-12.5 Z50.0 - Cutter starts from here with respect to the part zero (P1)
N04 G00 Z2.5 M03 S800 - Spindle on CW, move rapidly to 2.5mm above the part (P1)
N05 G01 Z-7.5 F25.0 M08 - Coolant on, plunge with feed in Z (P1)

Source: Altintas’s Mfg. Automation book

Machine Tool 12 IIT Kanpur

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Move to points P2, P3, and P4
N06 X162.5 F125.0 - Move in x with 125 mm/min feed to P2
N07 Y0.0 - Move to P3 at the same feed (125 mm/min)
N08 G02 X220.0 Y57.5 I57.5 J0 - CW circular interpolation (P4)

Source: Altintas’s Mfg. Automation book

Machine Tool 13 IIT Kanpur

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Move to points P5, P6, and P7
N09 G01 X232.5 - Move one cutter radius in the x-direction (P5)
N10 Y70.0 - Move in y (P6)
N11 G03 X180.0 Y122.5 I-52.5 J0 - CCW relative to the tool motion in block N10 (P7)

Source: Altintas’s Mfg. Automation book

Machine Tool 14 IIT Kanpur

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Move to points P8, P9, and P10
N12 G01 X107.5 Move left (P8)
N13 Y110.0 Move to (P9)
N14 G02 X80.0 Y82.5 I-27.5 J0 CW circular interpolation (P10)

Source: Altintas’s Mfg. Automation book

Machine Tool 15 IIT Kanpur

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Move to points P11, P12, and back to P1
N15 G01 X40.0 - Move left (P11)
N16 G03 X-12.5 Y30.0 I0 J-52.5 - CCW circular interpolation (P12)
N17 G01 Y-12.5 - Return to starting point (P1)

Source: Altintas’s Mfg. Automation book

Machine Tool 16 IIT Kanpur

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Move the tool back up, and end the program
N18 Z3.8 - Move up to z = 3.8mm position
N19 G00 Z50.0 M09 M05 - Move to Z = 50 rapidly, coolant and spindle are off
N20 M30 - Program ends.

Source: Altintas’s Mfg. Automation book

Machine Tool 17 IIT Kanpur

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Recounting the NC program

N01 G90
N02 G71
N03 G92 X-12.5 Y-12.5 Z50.0 (P1)
N04 G00 Z2.5 M03 S800 (P1)
N05 G01 Z-7.5 F25.0 M08 (P1)
N06 X162.5 F125 (P2)
N07 Y0.0 (P3)
N08 G02 X220 Y57.5 I57.5 J0 (P4)
N09 G01 X232.5 (P5)
N10 Y70.0 (P6)
N11 G03 X180 Y122.5 I-52.5 J0 (P7)
N12 G01 X107.5 (P8)
N13 Y110 (P9)
N14 G02 X80.0 Y82.5 I-27.5 J0 (P10)
N15 G01 X40.0 (P11)
N16 G03 X-12.5 Y30.0 I0 J-52.5 (P12)
N17 G01 Y-12.5 (P1)
N18 Z3.8 (P1)
N19 G00 Z50 M09 M05
N20 M30
*Note: () are not part of the program Source: Altintas’s Mfg. Automation book

Machine Tool 18 IIT Kanpur

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Exam question from 2019
Question 5 [2]

A workpiece with a diameter of 80 mm is provided to you. This has to be machined on a CNC lathe
machine to bring it down to the final dimensions shown below. Write a G code to do so. Start and end
at point ‘A’. Use the incremental mode of programming. Assume you can remove all material in a
single pass. The spindle speed must be 500 rpm, and the feed must be 0.2 mm/rev. Note that all
dimensions given are in mm. Include all the necessary preparatory and miscelleanous functions you
think are important for a full grade. Note that the sketch is not to scale.

% This program
Machine Toolassumes that the tool is already at ‘A’.
19 IIT Kanpur
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 % This program assumes that the tool is already at ‘A’.

Code Description
ssumes that the tool is already at ‘A’.
N01 G91 G71; Incremental mode and in SI units
N02 M03 S500 M08; Turn the spindle on to rotate at 500 RPM, and also turn on
the coolant
N03 G01 X-25.0 Z-40.0 F100.0; Move to point B with a linear feed of 100 mm/min – which is
obtained from the given feed in mm/rev multiplied by the
speed, i.e., 0.2 mm/rev x 500 RPM = 100 mm/min
N04 G01 Z-30.0; Tool moves to point C. X position remains unchanged
N05 G01 X20.0 Z-10.0; Tool moves to point D using linear interpolation
N06 G01 X5.0 Z 80.0; Back to point A
N07 M30; End of program

Machine Tool 20 IIT Kanpur

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Examples for you to figure G codes on your own

Source: Prof. Choudhury’s TA202A notes

Machine Tool 21 IIT Kanpur

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Examples for you to figure G codes on your own

Source: Prof. Choudhury’s TA202A notes

Machine Tool 22 IIT Kanpur

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Examples for you to figure G codes on your own

Source: Prof. Choudhury’s TA202A notes

Machine Tool 23 IIT Kanpur

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Alternatively, interpret this CNC code to figure the
shape of the part being made.

Example 1:

Source: Altintas’s Mfg. Automation book

Machine Tool 24 IIT Kanpur

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Alternatively, interpret this CNC code to figure the
shape of the part being made.

Example 2:

Source: Altintas’s Mfg. Automation book

Machine Tool 25 IIT Kanpur

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Exam question from 2019, and its solution
Question 4 [4]

Interpret the following NC program block by block. Correctly interpret the G and M functions for each
block and plot the complete tool path with the corresponding coordinates. Mark the corresponding
NC blocks on the tool path segments. For a complete grade mark each of the A, B, C, D, E, F, and G
points on the plot you will make. Also mark the features A1, A2, and B1 on the plot. Note that all
dimensions given are in mm. Your plot does not have to be to exact scale.
N01 G90; N15 G01 Z0; (Feature A1)

N02 G71; N16 G02 X-35 Y80.0 I0. J10.0; (Feature A1)

N03 G00 X0 Y0 Z50.0; N17 G01 Z50.0;

N04 M03 S900; N18 G01 X35.0 Y80.0; (Feature A2)

N05 G01 X0 Y0 Z0 F25.0; (Point A) N19 G01 Z0; (Feature A2)

N06 G03 X34.09 Y15.62 I0 J45.0; (Point B) N20 G02 X35 Y80.0 I0. J10.0; (Feature A2)

N07 G03 X58.63 Y77.74 I-34.09 J49.38; (Point C) N21 G01 Z50.0;

N08 G03 X24.79 Y119.64 I-6.63 J29.26; (Point D) N22 G01 X-15.0 Y30.0; (Feature B1)

N09 G03 X-24.79 Y119.64 I-24.79 J-54.64; (Point E) N23 G01 Z0; (Feature B1)

N10 G03 X-58.63 Y77.74 I-27.21 J-12.64; (Point F) N24 G03 X15.0 Y30.0 I15.0 J30.0; (Feature B1)

N11 G03 X-34.09 Y15.62 I58.63 J-12.74; (Point G) N25 G01 Z50.0;

N12 G03 X0 Y0 I34.09 J29.375; N26 G01 X0 Y0;

N13 G01 X0 Y0 Z50.0; N27 M05;

N14 G01 X-35.0 Y80.0; (Feature A1)

Machine Tool 26 IIT Kanpur

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Imagine the G codes for making this!

https://www.youtube.com/watch?v=IbV4vIYUg1U

Machine Tool 27 IIT Kanpur

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G code for a part like this?

Machine Tool 28 IIT Kanpur

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