1

A Seminar Report

On

CNC MACHINES

Report Submitted in partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted
By

Y. SOMESHU RAVI KIRAN 18ME5A0333

UNDER THE ESTEEMED GUIDENCE OF

Mr. K.P.V.S.R.VINAY KUMAR M. Tech
ASSISTANT PROFESSOR
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DEPARTMENT OF MECHANICAL ENGINEERING

(Approved by AICTE, New Delhi::Affiliated to JNTUK)
NBA, NAAC Accredited &An ISO 9001:2008 Certified Institution
NH 5 Bypass Road, Vatluru (V), ELURU-534007, W.G District, A.P
(2017-2021)
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C ERTIFICATE
This is to certify that the Seminar entitled “CNC MACHINES ” is a bonafied work carried
out by
Y. SOMESHU RAVI KIRAN 18ME5A0333

in partial fulfillment for the award of degree of Bachelor of Technology in Mechanical

Engineeringof Jawaharlal Nehru Technological University, Kakinada during the
A.Y:2020-2021.
To the best of my knowledge, the matter embodied in the thesis has not been submitted to
any other University / Institute for the award of any Degree or Diploma.

Place: Mr. K.P.V.S.R.VINAY KUMAR M.Tech

Date: ASSISTANT PROFESSOR
Department of Mechanical Engineering
RCEE

ACKNOWLEDGEMENT
Many individuals have contributed towards fulfillment of this work in one or many ways.
This work could not have seen light without the help of all these people. It will be my
pleasure and responsibility to acknowledge their contributions.

We are indebted to Sri. K. VENUGOPAL, Secretary and K. ROHIT, Managing Director, RCE
for providing with good academic and research environment in the department.

We are highly grateful to Dr. Dola Sanjay S, Principaland Dr. Jaya Lakshmi, Vice-Principal
for providing us with all the infrastructural facilities towards successful completion of this
work.
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We thank BHAVANARAYANA, HOD, Department of ME for his kind of cooperation. We

thank him from the bottom of our heart for providing and allowing us to use all the facilities
of the department.

We would like to express our deep sense of gratitude to our guide Mr. K.P.V.S.R.VINAY
KUMAR , Professor, Department of ME for his valuable guidance, constant encouragement
and fruitful suggestions during the entire period of this dissertation work.

We thank all the teaching and non-teaching members of the department for their help and
encouragement.

Last but not least, we thank my parents, friends, family and all my gurus who stood beside us
and taught us to stand against all odds in life. We also thank them for educating us in one or
other way. We thank almighty for blessing us with necessary strength, courage and a mind set
to understand technical aspects.

Y. SOMESHU RAVI KIRAN 18ME5A0333

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DECLARATION

I declare that the seminar entitled “CNC MACHINES” is compared by me and has not been
formed basis for the award of any degree, diploma, associate ship or other similar title or any
other university/institution.

Y.SOMESHU RAVI KIRAN 18ME5A0333

1
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Reading Materials for IC

Training Modules

Computer
Numerical
Control
(CNC)
IC PROFESSIONAL TRAINING SERIES

Last updated at AUGUST 2009

 1

Copyright reserved by INDUSTRIAL CENTRE, THE HONG KONG POLYTECHNIC UNIVERSITY

 Computer Numerical Control (CNC)

CCoommppuutteerr
NNuummeerriiccaall
CCoonnttrrooll
((CCNNCC))
Objectives:

19 To understand the working principle and applications of CNC machines. 19

To be able to prepare CNC part programmes for machining 2-D
workpieces.
19 To understand the structure and flow of a CAM system.

Content:

Chapter 1 Numerical Control Fundamentals

Chapter 2 CNC Part Programming
Chapter 3 Computer Aided Manufacturing

Introduction

Computer Numerical Control (CNC) is a specialized and versatile form of Soft

Automation and its applications cover many kinds, although it was initially
developed to control the motion and operation of machine tools.

Computer Numerical Control may be considered to be a means of operating a

machine through the use of discrete numerical values fed into the machine, where
the required 'input' technical information is stored on a kind of input media such as
floppy disk, hard disk, CD ROM, DVD, USB flash drive, or RAM card etc. The machine
follows a predetermined sequence of machining operations at the
predetermined speeds necessary to produce a workpiece of the right shape and size
and thus according to completely predictable results. A different product can be
produced through reprogramming and a low-quantity production run of
different products is justified.

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Fig.1-1 CNC Machine Centre (Courtesy of Agie Charmilles)

The definition of CNC given by Electronic Industry Association (EIA) is as follows:

A system in which actions are controlled by the direct insertion of numerical

data at some point. The system must automatically interpret at least some
portion of this data.

In a simple word, a CNC system receives numerical data, interpret the data and then
control the action accordingly.

Chapter 1. Computer Numerical Control Fundamentals

Objectives:

29 To understand the working principle of CNC machines. 29

To understand the characteristics of the driving systems. 29 To
understand the characteristics of the feedback devices. 29 To
understand the applications of CNC machines.

1.1 Control Systems

1.1.1 Open Loop Systems

Open loop systems have no access to the real time data about the performance of
the system and therefore no immediate corrective action can be taken in case of
system disturbance. This system is normally applied only to the case where the
output is almost constant and predictable. Therefore, an open loop system is
unlikely to be used to control machine tools since the cutting force and loading of a
machine tool is never a constant. The only exception is the wirecut machine for which
some machine tool builders still prefer to use an open loop system because there is
virtually no cutting force in wirecut machining.

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Fig.1-2(a) Block Diagram of an Open Loop System

1.1.2 Close Loop Systems

In a close loop system, feed back devices closely monitor the output and any
disturbance will be corrected in the first instance. Therefore high system accuracy is
achievable. This system is more powerful than the open loop system and can be
applied to the case where the output is subjected to frequent change. Nowadays,
almost all CNC machines use this control system.

Fig.1-2(b) Block Diagram of a Close Loop System

1.2 Elements of a CNC System

A CNC system consists of the following 6 major elements:

a. Input Device
b. Machine Control Unit
c. Machine Tool
d. Driving System
e. Feedback Devices
f. Display Unit

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Fig.1-3 Working Principles of CNC Machines

1.2.1 Input Devices

a. Floppy Disk Drive

Floppy disk is a small magnetic storage device for CNC data input. It has been the
most common storage media up to the 1970s, in terms of data transfer speed,
reliability, storage size, data handling and the ability to read and write.
Furthermore, the data within a floppy could be easily edited at any point as long as
you have the proper program to read it. However, this method has proven to be
quite problematic in the long run as floppies have a tendency to degrade
alarmingly fast and are sensitive to large magnetic fields and as well as the dust and
scratches that usually existed on the shop floor.

Fig.1-4 Floppy Disk Drive on a CNC machine

b. USB Flash Drive

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A USB flash drive is a removable and rewritable portable hard drive with compact size
and bigger storage size than a floppy disk. Data stored inside the flash drive are
impervious to dust and scratches that enable flash drives to transfer data from place
to place. In recent years, all computers support USB flash drives to read and write
data that make it become more and more popular in CNC machine control unit.

Fig.1-5 USB Flash Drive on a CNC machine

c. Serial communication

The data transfer between a computer and a CNC machine tool is often
accomplished through a serial communication port. International standards for serial
communications are established so that information can be exchanged in an orderly
way. The most common interface between computers and CNC machine tools is
referred to the EIA Standard RS-232. Most of the personal computers and CNC
machine tools have built in RS232 port and a standard RS-232 cable is used to
connect a CNC machine to a computer which enables the data transfer in
reliable way. Part programs can be downloaded into the memory of a machine tool
or uploaded to the computer for temporary storage by running a
communication program on the computer and setting up the machine control to
interact with the communication software.

Fig.1-6 Serial communication port on a CNC machine

Direct Numerical Control is referred to a system connecting a set of numerically

controlled machines to a common memory for part program or machine program
storage with provision for on-demand distribution of data to the machines. (ISO

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2806:1980) The NC part program is downloaded a block or a section at a time into

the controller. Once the downloaded section is executed, the section will be
discarded to leave room for other sections. This method is commonly used for
machine tools that do not have enough memory or storage buffer for large NC part
programs.

Distributed Numerical Control is a hierarchical system for distributing data

between a production management computer and NC systems. (ISO 2806:1994) The
host computer is linked with a number of CNC machines or computers
connecting to the CNC machines for downloading part programs. The
communication program in the host computer can utilize two-way data transfer
features for production data communication including: production schedule, parts
produced and machine utilization etc.

Fig.1-7 Serial communication in a Distributed Numerical Control system

d. Ethernet communication

Due to the advancement of the computer technology and the drastic reduction of
the cost of the computer, it is becoming more practical and economic to transfer part
programmes between computers and CNC machines via an Ethernet
communication cable. This media provides a more efficient and reliable means in part
programme transmission and storage. Most companies now built a Local Area
Network (LAN) as their infrastructure. More and more CNC machine tools provide an
option of the Ethernet Card for direct communication within the LAN.

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Fig.1-8 Ethernet port on a CNC machine

Fig.1-9 Ethernet network in a Distributed Numerical Control system

e. Conversational Programming

Part programmes can be input to the controller via the keyboard. Built-in
intelligent software inside the controller enables the operator to enter the required
data step by step. This is a very efficient way for preparing programmes for
relatively simple workpieces involving up to 2½ axis machining.

Fig.1-10 Conversational Programming in a CNC controller

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1.2.2 Machine Control Unit (MCU)

The machine control unit is the heart of the CNC system. There are two sub-units in
the machine control unit: the Data Processing Unit (DPU) and the Control Loop Unit
(CLU).

a. Data Processing Unit

On receiving a part programme, the DPU firstly interprets and encodes the part
programme into internal machine codes. The interpolator of the DPU then
calculate the intermediate positions of the motion in terms of BLU (basic length unit)
which is the smallest unit length that can be handled by the controller. The calculated
data are passed to CLU for further action.

b. Control Loop Unit

The data from the DPU are converted into electrical signals in the CLU to control the
driving system to perform the required motions. Other functions such as
machine spindle ON/OFF, coolant ON/OFF, tool clamp ON/OFF are also controlled by
this unit according to the internal machine codes.

1.2.3 Machine Tool

This can be any type of machine tool or equipment. In order to obtain high
accuracy and repeatability, the design and make of the machine slide and the driving
leadscrew of a CNC machine is of vital importance. The slides are usually machined to
high accuracy and coated with anti-friction material such as PTFE and Turcite in
order to reduce the stick and slip phenomenon. Large diameter recirculating
ball screws are employed to eliminate the backlash and lost motion. Other design
features such as rigid and heavy machine structure; short machine table overhang,
quick change tooling system, etc also contribute to the high accuracy and high
repeatability of CNC machines.

Fig.1-11(a) Ball Screw in a CNC machine Fig.1-11(b) Ball screw structure

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1.2.4 Driving System

The driving system is an important component of a CNC machine as the accuracy

and repeatability depend very much on the characteristics and performance of the
driving system. The requirement is that the driving system has to response
accurately according to the programmed instructions. This system usually uses
electric motors although hydraulic motors are sometimes used for large machine
tools. The motor is coupled either directly or through a gear box to the machine
leadscrew to moves the machine slide or the spindle. Three types of electrical motors
are commonly used.

a. DC Servo Motor

This is the most common type of feed motors used in CNC machines. The principle of
operation is based on the rotation of an armature winding in a permanently
energised magnetic field. The armature winding is connected to a commutator, which
is a cylinder of insulated copper segments mounted on the shaft. DC current is
passed to the commutator through carbon brushes, which are connected to the
machine terminals. The change of the motor speed is by varying the armature
voltage and the control of motor torque is achieved by controlling the motor's
armature current. In order to achieve the necessary dynamic behaviour it is
operated in a closed loop system equipped with sensors to obtain the velocity and
position feedback signals.

Fig.1-12 DC Servo Motor (Courtesy of Flexible Automation)

b. AC Servo Motor

In an AC servomotor, the rotor is a permanent magnet while the stator is

equipped with 3-phase windings. The speed of the rotor is equal to the rotational
frequency of the magnetic field of the stator, which is regulated by the frequency
converter.

AC motors are gradually replacing DC servomotors. The main reason is that there is
no commutator or brushes in AC servomotor so that maintenance is virtually not
required. Furthermore, AC servos have a smaller power-to-weight ratio and faster
response.

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Fig.1-13 AC Servo Motor (Courtesy of Flexible Automation)

c. Stepping Motor

A stepping motor is a device that converts the electrical pulses into discrete
mechanical rotational motions of the motor shaft. This is the simplest device that can
be applied to CNC machines since it can convert digital data into actual
mechanical displacement. It is not necessary to have any analog-to-digital
converter nor feedback device for the control system. They are ideally suited to open
loop systems.

However, stepping motors are not commonly used in machine tools due to the
following drawbacks: slow speed, low torque, low resolution and easy to slip in case
of overload. Examples of stepping motor application are the magnetic head of
floppy-disc drive and hard disc drive of computer, daisy-wheel type printer, X-Y tape
control, and CNC EDM Wire-cut machine.

Fig.1-14 Stepping Motor (Courtesy Real-Time Microcomputer)

d. Linear Motor

A linear electric motor is an AC rotary motor laid out flat. The same principle used to
produce torque in rotary motors is used to produce force in linear motors. Through
the electromagnetic interaction between a coil assembly and a permanent
magnet assembly, the electrical energy is converted to linear mechanical
energy to generate a linear motion. As the motion of the motor is linear instead of
rotational, therefore it is called linear motor. Linear motors have the advantages of
high speeds, high precision and fast response. In the 1980s, machine tool builders

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started using linear motors with the common motion control servo drives in the
machine tool design.

Fig.1-15 Linear Motor (Courtesy of Renishaw)

Among different designs of linear motors, permanent magnet brushless motors

demonstrate a high force density, high maximum speed, and stable force constant.
The lack of a brushed commutator assembly has the advantages of fewer
maintenance, higher reliability and better smoothness.

An iron core brushless linear motor is similar to a conventional brushless rotary

motor slit axially and then rolled out flat. The unrolled rotor is a stationary plate
consisting of magnets tiled on an iron back plate and the unrolled stator is a moving
coil assembly consisting of coils wound around a laminated steel core. Coil windings
are typically connected in conventional 3 phase arrangement and
commutation is often performed by Hall-effect sensors or sinusoidal. It has high
efficiency and good for continuous force.

An ironless linear motor consists of a stationary U shaped channel filled with

permanent magnets tiled along both interior walls. A moving coil assembly
traverses between two opposing rows of magnets. Commutation is done
electronically either by Hall-effect sensors or sinusoidal. The ironless linear motor
has the advantages of lower core mass, lower inductance and no cogging for smooth
motion as the ironless motors have no attractive force between the frameless
components.

Fig.1-16 Ironcore and Ironless Linear Motor (Courtesy of ETEL)

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1.2.5 Feedback Device

In order to have a CNC machine operating accurately, the positional values and
speed of the axes need to be constantly updated. Two types of feed back devices
are normally used, positional feed back device and velocity feed back device.

a. Positional Feed Back Devices

There are two types of positional feed back devices: linear transducer for direct
positional measurement and rotary encoder for angular or indirect linear
measurement.

Linear Transducers - A linear transducer is a device mounted on the

machine table to measure the actual displacement of the slide in such a way
that backlash of screws; motors, etc would not cause any error in the feed
back data. This device is considered to be of the highest accuracy and also
more expensive in comparison with other measuring devices mounted on
screws or motors.

Fig.1-17 Linear Transducer (Courtesy of Heidenhain)

Rotary Encoders - A rotary encoder is a device mounted at the end of the

motor shaft or screw to measure the angular displacement. This device
cannot measure linear displacement directly so that error may occur due to
the backlash of screw and motor etc. Generally, this error can be
compensated for by the machine builder in the machine calibration
process.

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Fig.1-18 Incremental and Absolute Rotary Encoder

b. Velocity Feedback Device

The actual speed of the motor can be measured in terms of voltage generated from a
tachometer mounted at the end of the motor shaft. DC tachometer is essentially a
small generator that produces an output voltage proportional to the speed. The
voltage generated is compared with the command voltage corresponding
to the desired speed. The difference of the voltages can is then used to actuate the
motor to eliminate the error.

Fig.1-19 Tachogenerator (Courtesy of Callan)

1.2.6 Display Unit

The Display Unit serves as an interactive device between the machine and the
operator. When the machine is running, the Display Unit displays the present
status such as the position of the machine slide, the spindle RPM, the feed rate, the
part programmes, etc.
In an advanced CNC machine, the Display Unit can show the graphics simulation of
the tool path so that part programmes can be verified before the actually

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machining. Much other important information about the CNC system can also
displayed for maintenance and installation work such as machine parameters, logic
diagram of the programmer controller, error massages and diagnostic data.

Fig.1-20 Display Unit for CNC machines (Courtesy of Heidenhain)

1.3 Applications of CNC Machines

CNC machines are widely used in the metal cutting industry and are best used to
produce the following types of product:

• Parts with complicated contours

• Parts requiring close tolerance and/or good repeatability
• Parts requiring expensive jigs and fixtures if produced on
conventional machines
• Parts that may have several engineering changes, such as during the
development stage of a prototype
• In cases where human errors could be extremely costly
• Parts that are needed in a hurry
• Small batch lots or short production runs

Some common types of CNC machines and instruments used in industry are as
following:

• Drilling Machine
• Lathe / Turning Centre
• Milling / Machining Centre
• Turret Press and Punching Machine
• Wirecut Electro Discharge Machine (EDM)
• Grinding Machine
• Laser Cutting Machine
• Water Jet Cutting Machine
• Electro Discharge Machine
• Coordinate Measuring Machine
• Industrial Robot

Chapter 2. CNC Part Programming

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Objectives:

159 To understand the Dimension Systems in CNC Part Programming.

159 To understand the structure of a CNC Part Programme.
159 To understand the G-codes and other functions of a CNC Part
Programme.

2.1 Axis of motion

In generally, all motions have 6 degrees of freedom. In other words, motion can be
resolved into 6 axes, namely, 3 linear axes (X, Y and Z axis) and 3 rotational axes (A,
B, and C axis).

Fig.2-1 Axis of Motion

2.2 Dimension Systems

2.2.1 Incremental System

This type of control always uses as a reference to the preceding point in a

sequence of points. The disadvantage of this system is that if an error occurs, it will
be accumulated.

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Fig.2-2 Incremental System

2.2.2 Absolute System

In an absolute system all references are made to the origin of the co ordinate
system. All commands of motion are defined by the absolute coordinate
referred to the origin.

Fig.2-3 Absolute System

2.3 Definition of Programming

NC programming is where all the machining data are compiled and where the data
are translated into a language which can be understood by the control system of
the machine tool. The machining data is as follows:

a. Machining sequence classification of process, tool start up point, cutting

depth, tool path etc.
b. Cutting conditions spindle speed, feed rate, coolant, etc.
c. Selection of cutting tools.

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2.4 Programme Structure

Program Block Block Block Block End of start

#1 #2 #30 #31 Programme

Sequence Word Word

Number #1 #2

N002 G01 X12.0

Address Value

G 01 X
12.0
Fig.2-4 Structure of CNC Part Programme

A CNC programme consists of blocks, words and addresses.

a. Block
A command given to the control unit is called a block.

b. Word
A block is composed of one or more words. A word is composed of an
identification letter and a series of numerals, e.g. the command for a feed
rate of 200mm/min is F200.

c. Address
The identification letter at the beginning of each word is called address. The
meaning of the address is in accordance with EIA (Electronic
Industries Association) standard RS-274-D. The most common 'addresses'
are listed below:

Function Address

Sequence number N
Preparatory function G
Co ordinate word X, Y, Z
Parameters for Circular Interpolation I, J, K
Feed function F Spindle
function S Tool function
T Miscellaneous function M

An example of a programme is as follows:

N20 G01 X20.5 F200 S1000 M03
N21 G02 X30.0 Y40.0 I20.5 J32.0
2.5 Explanation of Words

2.5.1 Sequence Number (N Address)

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A sequence number is used to identify the block. It is always placed at the

beginning of the block and can be regarded as the name of the block. The
sequence numbers need not be consecutive. The execution sequence of the
programme is according to the actual sequence of the block and not the
sequence of the number. In fact some CNC systems do not require sequence
numbers.

2.5.2 Preparatory Function (G Address)

A preparatory function determines how the tool is to move to the programmed

target. The most common G addresses are listed below:

Code Function
G00 Point to point position at rapid feed
G01 Linear interpolation
G02 Circular interpolation, clockwise G03
Circular interpolation, anti clockwise G40
Cutter compensation cancel
G41 Cutter compensation, Left
G42 Cutter compensation, Right
G45 - G48 Other cutter compensation, if used
G70 - G79 Milling and turning cycle
G80 - G89 Drilling and tapping cycle
G90 Absolute dimensioning
G91 Incremental dimensioning

2.5.3 Co-ordinate Word (X/Y/Z Address)

A co-ordinate word specifies the target point of the tool movement (absolute
dimension system) or the distance to be moved (incremental dimension). The word
is composed of the address of the axis to be moved and the value and direction of
the movement.

Example: X100 Y-200

represents the movement to (100, 200). Whether the dimensions are
absolute or incremental will have to be defined previously
(using G90 or G91).

2.5.4 Parameter for Circular Interpolation (I/J/K Address)

These parameters specify the distance measured from the start point of the arc to
the centre. Numerals following I, J and K are the X, Y and Z components of the
distance respectively.

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2.5.5 Spindle Function (S Address)

The spindle speed is commanded under an S address and is always in revolution

per minute. It can be calculated by the following formula:

Surface Cutting Speed (m/min) × 1000

Spindle Speed =
π × Cutter Diameter (mm)

The following table gives the surface cutting speeds for some common materials:

Cutting tool Workpiece material

Material Al alloy Brass Cast Iron Mild Steel

HSS 120 75 18 30
Carbide 500 180 120 200

Example: S2000 represents a spindle speed of 2000rpm

2.5.6 Feed Function (F Address)

The feed is programmed under an F address except for rapid traverse. The unit may
be in mm per minute (in the case of milling machine) or in mm per
revolution (in the case of turning machine). The unit of the feedrate has to be
defined at the beginning of the programme. The feed rate can be calculated by the
following formula:

Feed Rate = Chip Load / tooth × No of Tooth × Spindle Speed

The following table gives the chip load per tooth of milling cutters cutting some
common materials:

Milling Cutter Chip load per tooth (mm/rev)

Material Al alloy Brass Cast Iron Mild Steel

HSS 0.28 0.18 0.20 0.13
Sintered Carbide 0.25 0.15 0.25 0.25

Example: F200 represents a feed rate of 200mm/min

2.5.7 Tool Function (T Address)

The selection of tool is commanded under a T address.

Example: T02 represents tool number 2

2.5.8 Miscellaneous Function (M Address)

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The miscellaneous function is programmed to control the machine operation other

than for co ordinate movement. The most common M functions are as follows:

Code Function

M00 Programme stop

M03 Spindle rotation clockwise
M04 Spindle rotation counterclockwise
M05 Spindle STOP
M06 Change of Tool
M08 Coolant ON
M09 Coolant OFF
M10 Clamp
M11 Unclamp
M30 Programme end and ready for another start

2.6 Steps for CNC Programming and Machining

The following is the procedures to be followed in CNC programming and

machining. The most important point is to verify the programme by test run it on
the machine before the actual machining in order to ensure that the programme is
free of mistakes.

a. Study the part drawing carefully.

b. Unless the drawing dimensions are CNC adapted, select a suitable
programme zero point on the work piece. The tool will be
adjusted to this zero point during the machine set up.
c. Determine the machining operations and their sequence.
d. Determine the method of work clamping (vice, rotary table,
fixtures etc).
e. Select cutting tools and determine spindle speeds and feeds.
f. Write programme (translate machining steps into programme
blocks). If many solutions are possible, try the simplest solution first.
It is usually longer, but better to proceed in this way.
g. Prepare tool chart or diagram, measure tool geometry (lengths, radii)
and note.
h. Clamp work piece and set up machine.
i. Enter compensation value if necessary.
j. Check and test programme. It is a good practice to dry run the
programme (i) without the workpiece, (ii) without the cutting
tools, or (iii) by raising the tool to a safe height. If necessary, correct
and edit programme and check again.
k. Start machining.

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2.7 G-codes in Part Programming

2.7.1 Absolute and Incremental Dimensioning (G90/G91)

G90 and G91 are used to control the dimensioning system that will be used in the
data input. In G90 mode, the dimensions will be recognized as absolute while in
G91 will be incremental.

2.7.2 Rapid Positioning (G00)

This is to command the cutter to move from the existing point to the target point at
the fastest speed of the machine.

Programme Format

G00 X
Y
Z

Z Y

Rapid
Traverse

Fig.2-5 Rapid Positioning

2.7.3 Linear Interpolation (G01)

This is to command the cutter to move from the existing point to the target point
along a straight line at the speed designated by the F address.

Programme Format

G01 X
Y
Z
F

Z Y

At Designated
Speed

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X Fig.2-6

Linear Interpolation

2.7.4 Circular Interpolation (G02/G03)

This is to command the cutter to move from the existing point to the target point
along a circular arc in clockwise direction (G02) or counterclockwise
direction (G03).

In this case, beside the target point, the radius or the centre of the arc is also
required. Most of the CNC systems nowadays still require the data of the arc centre
rather than the radius.

The parameters of the centre of the circular arc is designated by the I, J and K
addresses. I is the distance along the X axis, J along the Y, and K along the Z. This
parameter is defined as the vector (magnitude and direction) from the starting
point to the centre of the arc.

Programme Format
(Clockwise Direction)

G02 X
Y
I (XC - XS) J
(YC - YS)

Where
XC and YC is the coordinate of the centre, and
XS and YS is the coordinate of the start point of the arc.
Y I
Start point
(Xs, Ys)
J

End (Xc, Yc)

point

Fig.2-7 Circular Interpolation - Clockwise

Programme Format
(Counterclockwise Direction)

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G03 X
Y
I
J

Y I End

J (Xc, Yc)

Start point
(Xs, Ys)

Fig.2-8 Circular Interpolation - Counterclockwise

2.7.5 Cutter Compensation (G40/G41/G42)

In CNC machining, if the cutter axis is moving along the programmed path, the
dimension of the workpiece obtained will be incorrect since the diameter of the
cutter has not be taken into account.

Modern CNC systems are capable of doing this type of calculation which is
known as cutter compensation. What the system requires are the programmed
path, the cutter diameter and the position of the cutter with reference to the
contour. Normally, the cutter diameter is not included in the programme. It has to
be input to the CNC system in the tool setting process.

Final contour does not Final contour matches

Match with programme path with programme path

Programme Cutter path offset from

the programme path

Fig.2-9 Comparison of Tool Path with and without Cutter Compensation

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If the cutter is on the left of the contour, G41 is used. If the cutter is on the right of
the contour, G42 will be used. G40 is to cancel the compensation calculation.

Cutter n the
o

Cutter Rig r Co ht of the conto

Fig. on the 2-10 mpensation

Direction of

Cutte

Programme Example 1

Programme Explanation
N01 G90 Absolute Dimensioning

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N02 G00 X-30 Y-30 Z100 Rapid move to (X-30, Y-30, Z100)
N03 T01 Using Tool Number 1
N04 G00 Z5 S1000 M03 Rapid move to Z5;
start spindle clockwise at 1000rpm
N05 G01 Z-10 F100 Feed to Z-10 at 100mm/min
N06 G41 G01 X0 Y15 F200 Call up compensation,
cutter on the left feed to
(X0, Y15) at 200mm/min
N07 G01 Y66.564 From N07 to N15 is the contour cutting
N08 G02 X16.111 Y86.183
I20 J0
N09 G02 X93.889 Y86.183
I38.889 J-196.183
N10 G02 X110 Y66.564
I-3.889 J-19.619
N11 G01 Y26.247
N12 G02 X98.882 Y11.758
I-15 J0
N13 G01 X55 Y0
N14 G01 X15
N15 G02 X0 Y15
I0 J15

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N16 G40 X-30 Y-30 Cancel of compensation;

feed to (X-30, Y-30)
N17 G00 Z100 M30 Rapid move to Z100; programme end

Programming Example 2

PARTING OFF TOOL

T3 MACHINE ZERO X
40,30 FROM
TOOL CHANGING
POSITION

T2
LEFT-HAND
TURNING TOOL

T3

RIGHT-HAND T2
T1 TURNING TOOL
PATH ? B ?

TOOL CHANGING POSITION

100,200 FROM PROGRAMME ZERO T1
PROGRAMME PATH ?A?
ZERO

Programme Explanation
N01 G28 U0.1 W0.1; Return to Machine Zero
N02 G00 U-60.0 W-40.0; Rapid move to Tool Changing position
N03 G50 X200.0 Z100.0; Assign the Programme Zero
N04 G97 S2000; Assign revolution speed as 2000 rpm
N05 M03; Switch on spindle,
turning in forward direction
N06 T0101; Select Tool Number T1 and call tool offset
N07 G00 X0 Z42.0; Rapid move to (X0, Z42.0)
N08 M08; Switch coolant on
N09 G69 F0.15; Assign feed to be 0.15 mm/rev
N10 G01 Z40.45; Start cutting the Contour along path A
N11 G03 X 9.217 Z31.13 R5.8;
N12 X8.955 Z29.465 R1.556;
N13 G02 X 9.6 Z29.1 R1.48;
N14 G01 X11.142;
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N15 G03 X 11.142 Z25.4 R2.398;

N16 G01 X16.6 Z9.385;
N17 Z8.5;
N18 X20.6;
N19 Z-3.0; Finish Contouring
N20 G00 X200.0 Z100.0; Rapid move to Tool Changing Position
N21 T0100; Cancel tool offset
N22 T0202; Select Tool Number T2 and call tool offset
N23 G00 X21.0 Z9.385; Rapid move to (X21.0 Z3.985)
N24 G01 X16.6 F0.15; Start cutting contour along path B,
in 0.15mm/rev feed
N25 G03 X9.6 Z24.203 R34.2;
N26 G01 Z25.4;
N27 X14.0; Finish contouring
N28 G00 X200.0 Z100.0; Rapid move to Tool Changing position
N29 T0200; Cancel tool offset
N30 T0303; Select Tool Number T3 and call tool offset
N31 G00 X24.0 Z0; Rapid move to (X24.0 Z0)
N32 G01 X-0.5 F0.06; Part off in feedrate 0.06 mm/rev
N33 G00 X200.0 Z100.0; Rapid move to Tool Changing position
N34 T0300; Cancel tool offset;
N35 M30; Programme end

2.7.6 Other Functions

Modern CNC systems have some specially designed functions to simplify the
manual programming. However, since most of these functions are system
oriented, it is not intended to discuss them here in detail. The following
paragraphs give a brief description of commonly used functions in modern CNC
systems. The user should refer to the programming manuals of the machine for the
detail programming and operation.

a. Mirror Image
This is the function that converts the programmed path to its mirror
image, which is identical in dimensions but geometrically opposite about
one or two axes.

b. Programme Repetition and Looping

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In actual machining, it is not always possible to machine to the final

dimension in one go. This function enables the looping of a portion of the
programme so that the portion can be executed repeatedly.

c. Pocketing Cycle
Pocketing is a common process in machining. This is to excavate the
material within a boundary normally in zigzag path and layer by layer. In a
pocketing cycle, the pattern of cutting is pre-determined. The user is
required to input parameters including the length, width and depth of the
pocket, tool path spacing, and layer depth. The CNC system will then
automatically work out the tool path.

d. Drilling, Boring, Reaming and Tapping Cycle

This is similar to pocketing cycle. In this function, the drilling pattern is pre-
determined by the CNC system. What the user has to do is to input the
required parameters such as the total depth of the hole, the down feed
depth, the relief height and the dwell time at the bottom of the hole.

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Chapter 3. Computer Aided Manufacturing

Objectives:

299 To understand the flow of a Computer Aided Manufacturing System.

299 To understand the characteristics of the process Tool Motion Definition
in a CAM system.
299 To understand the characteristics of the process Data Transmission in a
CAM system.

3.1 Computer Aided Part Programming

In manual preparation of a CNC part programme, the programmer is required to

define the machine or the tool movement in numerical terms. If the geometry is
complicated 3D surfaces cannot be programmed manually.

Over the past years, lot of effort is devoted to automate the part programme
generation. With the development of the CAD/CAM system, interactive graphic
system is integrated with the CNC part programming. Graphic based software
using menu driven technique improves the user friendliness. The part
programmer can create the geometrical model in the CAM package or directly
extract the geometrical model from the CAD/CAM data base. Built in tool
motion commands can assist the part programmer to calculate the tool paths
automatically. The part programmer can verify the tool paths through the
graphic display using the animation function of the CAM system. It greatly
enhances the speed and accuracy in tool path generation.

3.2 Flow of A Computer Aided Manufacturing System

There are several computer aided manufacturing or CAD/CAM system available in

the market. Their basic features can be summarized below:

a. Geometric Modeling / CAD Interface

b. Tool Motion definition
c. Data Processing
d. Post Processing
e. Data Transmission

CAM

3D Geometry
Construction
Scanning
/Co/pCyo
Mpyill
CAD/CAM
CIAntDe/rCf
aAcMe

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Geometry
Files
Tool Motion Definition
definition
Machining
Parameter
TSoeoql uMeontcieo n Data
Processing

Post
Processing
NC
Program

CNC Machine

Fig.3-1 Flow Chart of a CAM System

3.2.1 Geometric Modeling / CAD Interface

The geometry of the workpiece can be defined by basic geometrical elements such
as points, lines, arcs, splines or surfaces. The two dimensional or three dimensional
geometrical elements are stored in the computer memory in forms of a
mathematical model. The mathematical model can be a wire frame model, a
surface model, or a solid model.

In addition, the geometric models can be imported from other CAD/CAM system
through standard CAD/CAM interface formats such as Initial Graphic Exchange
Specification (IGES). Initial Graphic Exchange Specification (IGES)

IGES is a graphic exchange standard jointly developed by industry and the

National Bureau of Standards with the support of the U.S. Air Force. It provides
transportability of 3-dimensional geometry data between different systems.
Throughout this system, geometrical elements from one system can be
translated into a neutral file standard and then from this standard into other format.

3.2.2 Tool Motion Definition

After the geometric modeling, machining data such as the job setup, operation
setup and motion definition are input into the computer to produce the cutting
location file (CL file) for machining the workpiece.

a. Job setup
This is to input the machine datum, home position, and the cutter
diameters for the CL file.

b. Operation setup
This is to input into the system the operation parameters such as the feed
rate, tolerance, and approach / retract planes, spindle speed, coolant
ON/OFF, stock offset and the tool selection etc.

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c. Motion definition
Built in machining commands are used to control the tool motion to
machine the products. This includes the hole processing, profile
machining, pocketing, surface machining, gouge checking, etc.

Fig.3-2 CAM System

3.2.3 Data Processing

The input data is translated into computer usable format. The computer will
process the desired part surface, the cutter offset surface and finally compute the
paths of the cutter which is known as the cutter location data file (CL file). The tool
paths can normally be animated graphically on the display for verification purpose.

Furthermore, production planning data such as tool list, set up sheet, and
machining time is also calculated for users' reference.

3.2.4 Post Processing

Different CNC machines have different features and capabilities, the format of the
CNC program may also vary from each other. A process is required to change the
general instructions from the cutter location file to a specific format for a particular
machine tool and this process is called post processing.

Post processor is a computer software which converts the cutter location data files
into a format which the machine controller can interpret correctly.
Generally, there are two types of post processor.
a. Specific Post Processor

This is a tailor-made software which output the precise code for a specific
CNC machine. The user is not required to change anything in the
programme.

b. Generic (Universal) Post Processor

This is a set of generalized rules which needs the user to customize into the
format that satisfies the requirements of a specific CNC machine.

3.2.5 Data Transmission

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After post processing, the CNC programme can be transmitted to the CNC
machines either through the off line or on line process.

a. Off Line Processes

Data carriers are used to transmit the CNC programme to the CNC
machines. It includes paper tapes, magnetic tape or magnetic disc.

b. On Line Processes

On line processes is commonly used in DNC operation and data is

transferred either serially or parallel using data cables.

Serial Transmission

Asynchronous serial transmission is most widely used in data

transmission and RS232C is the most popular asynchronous
standard. Built in RS232C serial port (9 pins or 25 pins) is available in
many computers. RS232C is inexpensive; easy to program and with
a baud rate up to 38400. However, its noise margin is limited up to
15 meters.

Parallel Transmission

Parallel transmission is commonly used in data transmission

between computers and external devices such as sensors,
programmable logic controllers (PLC) or actuators. One common
standard is IEEE488. It contains a 24 lines bus with 8 for data, 8 for
controls and 8 for ground. It can transfer data up to 1 Mbps for a
20-meter cable.

Local Area Networks

To enable the CAD/CAM facilities to run smoothly, it is desirable for

the facilities to be linked together. In the local-area network,
terminals can access any computer on the network or devices on the
shop floor without a physical hardwire with speed up to 300
megabits per second. For instance, Ethernet runs at 100Mbps which
is much faster than an RS232 serial communication (115.2kbps).

A LAN consists of both software and hardware design, which

governed by a set of rules called protocol. The design of software
enable controls of data handling and error recovery, while
hardware generates and receives signals, and media that carries the
signals. The protocol defines the logical, electrical, and physical
specifications of the network. The same protocol must be followed
in order to have an effective communication with each other in
the network.

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References

• Computer Numerical Control of Machine Tools, G.E.Thyer,

Heinemann Professional Publishing 1988

• The CNC Workshop, Frank Nanfara, Tony Uccello, Derek

Murphy, Prentice-Hall 2002

• CNC Programming, Michael Mattson, Delmar Cengage

Learning, 2010

• The Machining of Metals, Armsrego E. J. A., R. H. Brown,

Englewood Cliffs, N.J., Prentice-Hall 1969

• Managing Computer Numerical Control Operations, Mike

Lynch, Society of Manufacturing Engineers 1995

• International Standard ISO2806 Industrial Automation System –

Numerical Control of Machines – Vocabulary, International
Organization for Standardization

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